Honda S90 - Luggage Rack.


This page details a luggage rack which was designed to fit the Honda S90.

It was manufactured from cold rolled steel tubing of 14mm for the main frame and 12mm for the smaller cross pieces.

It was mounted using 4 fixing points. Two at the top of the rear shock absorber mounting and two on the rear indicator mounting points on the rear wheel arch.

 

 

 

 

 

 

 

 

To see the plans for this rack design, please click the image to the right. However please note that these dimensions worked on my bike but yours may be different. In particular it is recommended that mountings at the indicator points are made to suit not just taken from the sketch.

Click to enlarge

 

 

 

 

 

 

 

 

First a piece of long 14mm tubing was bent in 2 places to form the outside frame of the rack.

Mounting drilled 8mm

This frame was then cut to final length and each end had a short section filed half-way through. Then a piece of drilled plate was brazed to each end.

 

 

 

 

 

 

 

 

The frame was put in place on the bike without the seat to ensure that it would fit and that everything was square.

 

 

 

 

 

 

 

 

With the seat back in place, two bits of 14mm pipe were cut and bent to form the grab rail and the front cross piece. Both these parts had radii filed in the ends to fit neatly against the side of the existing 14mm tube.

Then the rack was removed from the bike and the 2 parts brazed in place. A piece of 8mm threaded rod was used to hold the ends together during the joining process

Rack with grab handle and cross piece in place

 

 

 

 

 

 

 

 

To finish the loading area of the rack two 12mm pieces of piece were cut and filed to fit and then brazed in place.

Click to enlarge

 

 

 

 

 

 

 

 

This photo shows the rack fitted in place using the 2 shock absorber mountings. At this point it was still resting on the rear indicators.

Click to enlarge

 

 

 

 

 

 

 

 

These images show the components used to mount the rack to the indicator mountings on the rear wheel arch. The stand off was 53mm long. It had an M6x1 hole tapped in one end and an external M6x1 thread on the other. The external thread was 6mm long.

The plate was a piece of 5mm steel. Cut to size and drilled as shown. This part was designed so that the indicator screw would also be used to screw the stand-off and plate together. One hole was slotted so that the indicator could be mounted without having to break and re-join the wire. The top of the mounting plate was filed to sit neatly against the 14mm tubing.

 

 

 

 

 

 

 

 

To braze the plate in the correct place the rack was assembled on the bike and the plate was clamped in place. Then the rack was removed from the bike and the plate brazed in the hearth. This was the only way to ensure that the plate was accurately positioned both linearly and angulaly.

The process was repeated on the second side.

 

 

 

 

 

 

 

 

The two photos below show the plate screwed to the stand off using the standard indicator screw. The stand-off secured the rack to the rear wheel arch and also provided an outboard mounting position for the indicator. If preferred, an alternative position for the indicators would be lower down either side of the number plate and there are commercial units available to do this. However this would need longer wires on the indictors whereas the design here could be installed and removed without any adjustment to the wiring.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The photo below left shows the rack cleaned up and with all the fabrication finished. The right one shows it painted with some black enamel paint. A better looking rack could have been made out of stainless steel as then it could have been left unpainted.

Rack finished - Click to Enlarge

Rack Painted - Click for larger image

 

 

 

 

 

 

 

 

Finally - some images of the rack assembled on the bike.

After fitting the indicators had to be checked for correct operation.

 

 

The rack looked just right when used with my work case.

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