Beefing up a$$ end of a 650-R

[Zapp22]

I just installed the Dirtz Bagz subframe extension for the BRP and it is mighty stout, and inexpensive. How to put a rack on there I haven't figured out yet, but the steel that subf-ex is made of is HARD.... i broke a couple of tools trying to slightly move the tab screw-mount, then got smart and moved the fender hole a tad.

i dunno how much weight this thing can take but it is RIGID.

if anyone has an idea for a rack, pls post. Otherwise, its homemade! maybe a couple of small barbecue/hibachi grilling racks......

[InternalCombustion]

Photos??

I went to the Dirt Bagz / Moto-Sport Panniers website but not any pics of the extention you refer to...

Thanks!

[Zapp22]

Photos??

I went to the Dirt Bagz / Moto-Sport Panniers website but not any pics of the extention you refer to...

Thanks!

http://moto-sportpanniers.com/dirtbagz/extras.htm

upper right hand corner.

btw... the cortech gloves are good. i got the largest size and they work out really swell.

[gaspipe]

I modified a set of the Dirt Bagz brackets to work with the Pro Moto Billet rack. It's much, much better than the SRC brace and rack. It just survived a long, grueling Mexico trek and never lost nor loosened a screw.

The 6mm bolts from the rack brackets into the rear subframe are too small. These need to be upgraded to 8mm bolts if you're going to carry anything heavier than a bag of Doritos.

[Zapp22]

Gaspipe, you DO get around!

can you 'splain how to make that rack work? did you drill straight through the fender and through the DB rail to screw the thing on or ??? clamps somehow?

Also, which tank is that you're running? looks good. stock seat or ??

[pburke]

Also, which tank is that you're running? looks good.

I think the brand name is on the picture - look again

[Zapp22]

got it, thanks.

another thread on tanks. how do i pick IMS/Clarke/Acerbis/other?

[gaspipe]

Gaspipe, you DO get around!

can you 'splain how to make that rack work? did you drill straight through the fender and through the DB rail to screw the thing on or ??? clamps somehow?

Also, which tank is that you're running? looks good. stock seat or ??

Zapp -

I got tired of the SRC rear rack/fender brace falling apart during each ride - now granted each ride I've done on this rig is 2,000+ miles. Nevertheless, it never survived a trip without being ziptied together. So I abandoned the SRC system even though they were good to work with and kept sending me replacements.

I decided to use a ProMoto Billet rack and make that work with the DirtBagz hoops. First, the 6mm bolts that attach the rack to the subframe need to be upgraded to 8mm. That gives a 75% increase in cross sectional area of the bolt Drill out the PMB mounts and the 6mm threads in the subframe, and tap the subframe for the 8mm bolts. I have one subframe with steel inserts and one with aluminum threads. Both hold up fine. Lastly, I very, very carefully fitted the mounts to the subframe - this is critical as you don't want wallered out holes or a loose fit anywhere. That's what starts the failure cycle.

Next, I assembled the rack on the bike using urethane windshield adhesive between all the bolted together parts. I also used blue locktite to threadlock everything. There's no need for red.

The next step is a blob of silicone over the bolt heads for the rack subframe mount. I've never lost a bolt this way.

My plan was to use the DirtBagz on the XR. I love these things, as even the small bags hold enough for me to travel for weeks. I travel light. Anyway, I wanted to used the steel hoops as another support point for the rack, as I don't like the way all the weight of the rack is cantilevered on the rack.

Now, the DirtBagz hoops for the XR650R won't work with the PMB rack, but they can be MADE to work if you have a welder handy. I cut the ends off the rack, made new bends and flanges, and welded them back together. I bet a call to MotoSport Panniers can yield a set of hoops that would be easier to work with then the original XRR hoops. The flanges attach to the sides of the rack, and lend a good deal of support to the rack. I can sit on it and it doesn't move. The bolts attaching the flanges to the rack are 6mm grade 12.9 alloy ones with nylock nuts.

Pics of the final deal that survived a rugged haul through Mexico....

The flanges:

Side shot:

This was easy to do, and when I finished, I coated them with truckbed liner.

The next thing to do, that I'm working on now, is mounting a 6" long LED tailight from a trailer into a piece of 2024 sheet aluminum that will attach from the rear of the PMB rack to the rear fender. That will eliminate two more problems - 1) the horrifically crappy dual sport tailight will be replaced by a BIG RED LED, up high where it will be visible, and 2) it will become the fender support so that fender isn't wiggling all over the place.

When I finish it, I'll post that here.

HTH,

GP