Water-jet cut rear rack - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum

imagineer · 04-02-2012, 10:17 AM

Since I have to learn the software for a new water-jet system where I work, I decided to have a little fun with some scrap aluminum…a rear fender rack.

After routing the edges with a 1/8” round over bit (w/ a dremel), bending and a lot of polishing (2 hours), here it is installed.

It looks ok, but I’m not all that pleased with the final results. First, I used the wrong alloy of aluminum. I should have used a 6061, but I’m guessing this material is 3003. It’s too soft and does not polish well. 2nd, I’m not happy with the bend. Having only a Harbor Freight hydraulic press available, I was not able to get a consistent radius bend. If I can find the time, I’m going to build a slip roller designed for bending ¼” aluminum.
The brackets are also water-jet cut from .070” steel and painted with black plasti-dip. The front bracket is slotted so to make it “quick(er) release” like my pillon seat.
I’m planning to try making others and in the process, incorporate custom design or logo. The next one to try is a flat version with a compass logo in the center (a friend’s business logo) that will bolt to the passenger back rest on his Yamaha 1300.
I’m not all that artistic, so if you have any comments for improvement or custom design ideas, please send them along. Maybe I can make a few of these for VR members.

**kettlinton** · 04-02-2012, 10:25 AM

From the pics it looks GREAT!!!

~Capt Creole~ · 04-02-2012, 10:33 AM

That looks sharp as he!!.....

You could sell a buttload of those if you offered them up.

**Rob 61** · 04-02-2012, 10:41 AM

I think that is cool. I do see what you mean about the polishing. I need a radiator cover made, if you need more practice on the software

Westlander · 04-02-2012, 11:10 AM

I would like one if you decide to sell them..

Tanker2Biker · 04-02-2012, 11:43 AM

Looks excellent, the width and spacing of the bars looks great.

I happen to be partial to the flat rack as opposed to curved, but it looks like you captured the fender curve very well.

dliddell · 04-02-2012, 11:55 AM

nice job

rhollandphoto · 04-02-2012, 11:56 AM

Looks great. One idea: You could make the front bracket a "notch out" like the passenger seat to there's only one bolt to remove when swapping it out. I did that to a stock rack i bought.

imagineer · 04-02-2012, 12:21 PM

Quote:

Originally Posted by rhollandphoto

Looks great. One idea: You could make the front bracket a "notch out" like the passenger seat to there's only one bolt to remove when swapping it out. I did that to a stock rack i bought.

That's exactly what I did, look at the 2nd pic. I added short spacers under the bolt heads to profide space for the notched bracket to slip into. Because there will have to be a small amount of clearance needed for the bracket to fit, I make the angle of bend in the front bracket to be a bit less than what is necessary for the rear bracket to rest on the mount on the fender. By having to "force" the rear bracket into position, a small amount of tension is aapplied to the front bracket, reducing the possibility of it rattling.

I appreciate the all comments. If you have a custom design in mind, send me a pm with you email and we'll see if something can be designed. Like I mentioned earlier, I'm not very artistic, but I can design most anything in AutoCAD.

philkaos · 04-02-2012, 02:41 PM

Ok my only question is..... WHEN WILL YOU MARKET THEM????? That is creative and it's pretty amazing at that.

04-02-2012, 10:17 AM	#1 (permalink)
imagineer Senior VR Member Join Date: Feb 2010 Location: North East Ohio Posts: 763 Thanks: 13 Thanked 95 Times in 55 Posts	Water-jet cut rear rack Since I have to learn the software for a new water-jet system where I work, I decided to have a little fun with some scrap aluminum…a rear fender rack. After routing the edges with a 1/8” round over bit (w/ a dremel), bending and a lot of polishing (2 hours), here it is installed. It looks ok, but I’m not all that pleased with the final results. First, I used the wrong alloy of aluminum. I should have used a 6061, but I’m guessing this material is 3003. It’s too soft and does not polish well. 2nd, I’m not happy with the bend. Having only a Harbor Freight hydraulic press available, I was not able to get a consistent radius bend. If I can find the time, I’m going to build a slip roller designed for bending ¼” aluminum. The brackets are also water-jet cut from .070” steel and painted with black plasti-dip. The front bracket is slotted so to make it “quick(er) release” like my pillon seat. I’m planning to try making others and in the process, incorporate custom design or logo. The next one to try is a flat version with a compass logo in the center (a friend’s business logo) that will bolt to the passenger back rest on his Yamaha 1300. I’m not all that artistic, so if you have any comments for improvement or custom design ideas, please send them along. Maybe I can make a few of these for VR members. __________________ '05 C90, 3" HK Long Straights w/ SmartPartz Baffles, Cobra FI2000, K&N Filter, SLOB Mod, MS Batwing, Hardstreet Slim Bags, Pass to flash garage door opener, custom shift & brake levers, tachometer "There are no simple projects" Last edited by imagineer; 04-02-2012 at 10:23 AM.

04-02-2012, 10:25 AM	#2 (permalink)
kettlinton Super Moderator Join Date: Dec 2008 Location: Owings Mills, MD Posts: 3,046 Thanks: 1,503 Thanked 532 Times in 328 Posts	From the pics it looks GREAT!!! __________________ 2007 C50(Sold) 2005 Vulcan 1600 Classic(Totaled due to Deer) 2002 Honda VTX 1800S(The Beast!)

04-02-2012, 10:41 AM	#4 (permalink)
Rob 61 Super Moderator Join Date: Jun 2007 Location: Va Bch Posts: 2,508 Thanks: 115 Thanked 317 Times in 248 Posts	I think that is cool. I do see what you mean about the polishing. I need a radiator cover made, if you need more practice on the software __________________ Robyn Ray II, 07 C50 10/11 11 Victory Cross Country 3/11-1/12 04 Volusia 7/07-4/11 ^^^^^^^^ I'm on top

04-02-2012, 11:56 AM	#8 (permalink)
rhollandphoto VR Member Join Date: Mar 2011 Location: Stuart, Florida Posts: 204 Thanks: 26 Thanked 25 Times in 22 Posts	Looks great. One idea: You could make the front bracket a "notch out" like the passenger seat to there's only one bolt to remove when swapping it out. I did that to a stock rack i bought. __________________ Robert 2007 Yamaha V Star 1300 2005 C50 (sold)

04-02-2012, 11:43 AM	#6 (permalink)
Tanker2Biker Senior VR Member Join Date: Dec 2010 Location: Spring, TX Posts: 604 Thanks: 27 Thanked 118 Times in 74 Posts	Looks excellent, the width and spacing of the bars looks great. I happen to be partial to the flat rack as opposed to curved, but it looks like you captured the fender curve very well.

04-02-2012, 11:55 AM	#7 (permalink)
dliddell VR Member Join Date: Jun 2011 Location: Bradenton Florida Posts: 206 Thanks: 34 Thanked 19 Times in 19 Posts	nice job

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