Custom Givi Wing Rack Mount for 3rd Gen

Project#1: Custom Givi Wing Rack Mount for 3rd Gen
One of my plans for next year is to do some longer distance touring, but I have found that the current Soft bags really do not cut it, so I wanted to add hard-bags.
The Hard bags will provide better security for my belongings when commuting to work, be more weather tight and they will be easier to take on and off than the soft bags
Since the Mount kits for the 3rd Gen are long out of production, I have two choices, wait for a used set to come up ... Or fab up my own.

I chose option#2 (Fab them up)
I found a Givi Wingrack (NOS) that was a dealer display that I grabbed Cheap. Last week I got a set of Givi E41's at a good price.
I picked up some mild steel flat bar, round bar and 3/8" tube to fabricate the mounting adaptors/brackets to attach the wing rack to the bike.

I figured I would Share the Process of this little project

All the bits ...


Mocked up the Wing Rack - using Zip ties to get an idea of the rough placement so I could get an idea of the clearances and mounting options for the hard-points.



I then attached the Bags to see the actually placement and clearance ... it definitely has to move rearward to allow comfortable access to the passenger pegs.
But I am excited ... I think it will work well and look pretty good.




Rolled the bike up onto the work stand and striped it down




when I stripped it down I noticed 3 lovely threaded bungs on the sub frame




So I measured up some 1.0 x 0.125 cold-rolled flat bar and made two straight tabs that I could bolt up and lie the tail section up against to figure where the bends need to be to clear the body work





Used my Nifty Bracket bender for the bench vice to form the tabs to fit the profile of the bodywork





TA DA ... This become this




Attached the first set of brackets, rotated the Givi rack to where I wanted it, and snugged down the bolts




Then re-installed the tail section, took some measurements and made the 2nd set of brackets (More vertical ones)








Now I have the rear brackets fabbed (Triangulated) I need to fab the front bracket
It was a bit convoluted in terms of fitting it, so I grabbed some copper wire to make a template I could use to bend the flat bar to.





This was fitted, tweaked and installed





Reinstalled the tail-section to check clearances ... I am pretty happy with the result so far.
No Body work needs to be trimmed, only the under tray





Tack welded the brackets in place




Took them over to the bench and Tig'ed them up (Bit rusty it has been a year or so since I have used the Welders)





Installed them on the bike




I think I am going to add this arched lower brace (Tabed and bolted inplace) to increase stiffness and stop the weight of the bags roll the bottom of the bags inward and downward.



Pictures with the bags mounted





I will provide further updates as things move along

Moose

 

YUP - with the mounts cantilevered out from the sub-frame the weight of the bags will want to rotate the mounts down and in. All that is currently preventing this is the stiffness of the bar-stock, which has been weakened by the required bends to clear the bodywork.

I plan to gusset (where possible), add the rear hoop to triangulate the rear of the mount stiffening it up. BUT I think the biggest gain will be by tying the Givi mount into structure that is closer to vertical over the mount. The obvious way to accomplish this is to use the passenger grabs handles. I am going to look into a couple of options ...
1- using an oversized P-Clamp around the grab handle which will bolt to a tube that ties vertically into the Wing Rack
2-Drill a hole in the grab handles to allow me to bolt a support to a tube that ties into the Givi Rack.
3-A custom support that replaces completely the grab handle with a new grab handle and hard-mount to the Givi Rack

The rear stiffening hoop and a vertical support tied to the grab handles is my next step in this build.

I will add other gusssets/supports as required

As for looking good … Thanks …. but only at 6’+ … she is a bit rough due to a few lay downs by the PO - the crappy camera phone hides many blemishes


Cheers

Moose

 

Decided to add a vertical support that tied into the passenger grab handles

I Measured and bent up some brackets that tied into a upper mount on the Givi Wingrack, then I
Drilled and bolted it to the grab handles




Then I decided to work on the stiffening support that helps tie the lower part of the give brackets together
Made up a short tab, drilled and bolted it to the existing mount.



Tack welded the hoop in place and then fully welded it on the bench




I am pretty happy with the latest brackets, they add a huge amount of stiffness to the Givi Rack.
There is very little deflection in the bracket itself.

That’s it for now on the Givi mount, I will sand and prep it at some point and then put a couple coats of black paint on it.


Cheers
Moose

 

...and I used to think I was the only dude around that was a serious traffic cone collector. This thing may go viral.

 

Hahaha .... those were legally aquired, They are just being stored off season (Auto-X) for the club I belong to.

 

At least now you can store some of those cones in your panniers and topcase. There are cone thieves everywhere.

 

That is a nice way of doing things ... I was trying to figure out a way to get the stiffness required, to maintain the arc, without having to goto stupid thick bar-stock that would be difficult to bend.

Using the channel is brillant - notched it will be reasonably easy to form and welded up it will retain most of the strength due to the crosssection

Thanks

Moose

 

Nice job. I used my rear peg bolts as another anchor point.

You can also put a piece of flat stock between the bags for stiuffness right behind the plates.

Larry
VFRrider

 

Nice metal working skills. Great pictures too, an air-activated table would make you happier than a pig in shate. :smile: cheers - :drinkers:

 

Yeah tell me about it .... I have been resisting THAT temptation (and a metal bandsaw, and a OxyAcet torch, and ... ) , too many other house and bike related expences and projects right now .... $40 worth of lumber to save my back will have to do for now

I think I am going to give that a shot next ... I do not love the existing bracket that ties into the grab handles ....they are not a great (looking) solution ....Thanks again

I had a similar thought (Givi uses that in one of their OE style brackets) ... that will be easy enough to add if she starts to sag.


The Givi rack is 90-95% done ... just enough left to tinker with over the winter.


Cheers

Moose

 

My install was similar. I had the two arms that attached to the bungs on the subframe, and that was triangulated with those 5th gen arms to the passenger pegs. Fit was not quite right, as expected with mixing and matching. But I loosened the whole thing and added a couple round spacers down at the pegs (& longer bolts), and everything is solid.

http://www.vfrdiscussion.com/forum/uploads/gallery/album_6396/med_gallery_6373_6396_2811988.jpeg

 

Hi, here is the original fitting instruction of 3rd gen Givi Wingrack.

 

This is still very helpful for us 3rd genners out here. Molto grazie, amici!