Not quite sure what you're aiming for, but maybe this will help.
I made a rack extension on my DR650 a few years ago that worked quite well. I carried a spare rear tire through Turkey and into Central Asia on it.
I built the rack from an old fibergass/wood cross country ski- very strong with a little flex in it. The ideal material, I think and easy to work with. It was u-bolted to the stock Suzuki rack. The idea was to keep the tire on the bottom of my gear, without taking up too much room on my seat, and to keep it from blocking the view of my taillight, not to mention, out of the hot exhaust gases.
Here it is in action in Slovenia.
............shu
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