Heres pics of parts needed to assemble the actual rack. These are all the parts nessecary except for gas tank brackets.
Pic 1
starting with part #1.
2 @ 16''
These are the rear verticals . I usually use 1 1/2 inch angle iron for these. The bike i'm building needed new forks as the old ones were bent. I decided to cut up the old ones and use the forks as verticals.
Because I'm building on a beach cruiser style frame , I figure the curved forks might suit the frame better than straight iron.
Parts 2, 3 . and 4 are all 1 1/2 '' angle iron. I used a rusty old bedframe some one had tossed.
Part #2
these are the 2 side rails
2 @ 15 ''
part #3
the 2 front mounting brackets
Make 2 @ 10 ''
Part #4
2 jack axle mounts
Make 2 @ 5 ''
Parts #5 and #6 , I made out of aluminum just because I had it. Most of the time I just use steel flat stock.
Part #5
Front rack plate
Make 1 @ 2'' by 9 ''
Part # 6
Rear rack plate/ motor mount
Make 1 @ 4 1/2'' by 9 ''
You'll see the one in the pic is actually 6'' by 9'' and I've cut notches for the primary chain and exhaust. This is extra work with no real benifit but maybe a little more structural integrity.
Ideally it should have a couple extra inches at a rightangle at the back to keep it from flexing under torque .
see pic 4 to get a better idea of what it should look like . I've blacked out the unnessecary part.
Parts
#5 and #6 should be thicker than the angle iron as theres abit of pressure on them and these
should not flex under load.
I do not weld . I use 1/4 '' bolts at 3/4 '' long for the entire project.
Get 24 of these bolts, nuts, and lock washers. You'll need 2 2 1/2'' inch bolts also. these will be 1/4 '' aswell. and a 1/4 '' drill bit.
I use a cut off blade in my grinder to do all the cutting.
If you weld or can get it welded , by all means but do not weld parts #1 and #4.
Next post we'll assemble.
Cheers
~Haggard