Hi Cliff.
There are extensive posts on making racks, there are numerous threads detailing the manufacture including pictures for both metal and pelican case type racks.
I presumed you had researched these prior to posting right?
Most people dont take the long route of building their own rack, they just fork out the cash and buy one. Many of these posts conclude with someone buying a rack, or modifying the touratech racks.
My simplistic response was an illumination as to the material costs. which as you have expressed a concern, I thought may interest you.
As for; how hard it is, well, I'm on my second 8m set as I buggered up the first 8m.
By way of a peaceful response heres a pictoral link to someone elses handy work whose solution may inspire you. Suzuki DR 650 SE pannier rack
Regrads G
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