T2W How To: Custom Rear Rack for KLR650 – Part 1

In part 1 of this How To episode, I am fabricating a custom rear rack with interchangeable top plates for my 2009 KLR650.

Part 1 covers “the plan” with design and layout.

Part 2 covers “the build” including drilling, tapping, welding, demo of the AdMore Light Bar, and changing the top plates.

Want to donate? – https://www.paypal.me/tim2wheels

KLR-650 Repair Manuals
Clymer Repair Manual for KLR650 (Gen 1 1987-2007): https://amzn.to/2wPJOaX
Clymer Repair Manual for KLR650 (Gen 2 2008-2012+): https://amzn.to/2wNMlCE

Drawing/Plans for this Project (PDF file) can be downloaded at http://tim2wheels.com/documents/

Online Metals: http://www.onlinemetals.com/
Bolt Depot: https://www.boltdepot.com/
AdMore Lighting: http://www.admorelighting.com/

The Information provided in this video IS NOT professional advice. It is simply a demonstration of how I performed this task and is for informational purposes only.
If you are not comfortable performing this mechanical work, seek professional assistance.
Always follow the manufacturer’s instructions when performing maintenance or installing parts and equipment.

5 Replies

  1. Cliff Spicer Reply

    These are great videos but too challenging for a mere mortal like me. You make me wish I would have paid more attention in shop class.

  2. HJH413 Reply

    Nice videos. Got a new subscriber here.

  3. BigAzz J Reply

    Great vids! I have a 2015 and getting ready to mod

  4. jlacerda14 Reply

    Dear Tim, first of all I want to congratulate you for such an informative video. I recently bought a 2014 KLR and want to install a Givi Topcase just like yours. For that I have a question: on minute 3:20 you're holding the KLR rack plus the mounted plate, did you have to make any mods to the rack in order to install the plate? Thank you in advance.

    Regards from a ADVrider from Perú.

  5. Steve Smitherman Reply

    I really like these KLR videos. Im planning on buying a klr this summer.