XR650R Dual Sport Project & Travels

XR650R Saddlebag Solution

To provide luggage I purchased tank panniers from Aerostich to use as saddlebags, but I needed a way to mount them.  The King-Lar Company, a local sheet-metal fabricator, came up with this great solution.  The rack is sturdy and light; just right for the job.  The fasteners are metric, using the same hex key as the RACK-IT.  These photos show the smaller "Competition" panniers.  Later I bought the larger standard size.  I like the larger ones better.

The design uses all the original RACK-IT parts, but adds two brackets and two aluminum plates.  The bags hang from straps and are secured to the plates with bunge cords.	Here are all the parts.  The plates are heavy enough for the job, but light enough to bend back into shape after an impact.	Inside view of left bracket.	Outside view of right bracket.  The plates bolt against the inside surface at the counter-sunk holes.  The RACK-IT top rack fits over the upper holes.
Top view of right bracket.	The bar welded to the outside of the brackets accomodates a single bag, if desired, but isn't used for dual bags.	Assembled without bags.  This also shows the XR650L rear turn signals I mounted on a home made bracket.	A sleeve sewn to the bike-side surface of each bag secures bunge cords.  Neoprene pad cushions hard objects and provides grip against the aluminum plates.
Here is is all put together.	This shows it with two liters of water in each bag.  I'll travel with 1L in the bags and 3L in a Camel Back.	If this isn't a somewhat heavy dirtbike I don't know what is.  As a dirt-worthy long distance dual sport though, it ought to be the bee's knees!