1/2" square for pannier mounts--OK?

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I'm helping a fellow add pannier mounts to his motorcycle's OEM rack.  You can see what someone else's finished product looks like in the pic below.The gentleman wants to go as light as possible and will not be mounting big metal boxes, rather he intends to use smaller Pelican 1430 cases which are 5.6 lbs empty.  So maybe 20 lbs loaded (that's a WAG on my part).Can he get by using 1/2" (vs. 3/4") square?  The cases will mount with some sort of puck system, they won't thread through the square stock.You can see a few more pictures here.MM180
Reply:[quote=Tempo;206274]I'm helping a fellow add pannier mounts to his motorcycle's OEM rack.  You can see what someone else's finished product looks like in the pic below.The gentleman wants to go as light as possible and will not be mounting big metal boxes, rather he intends to use smaller Pelican 1430[/URL] cases which are 5.6 lbs empty.  So maybe 20 lbs loaded (that's a WAG on my part).Can he get by using 1/2" (vs. 3/4") square?  The cases will mount with some sort of puck system, they won't thread through the square stock.You can see a few more pictures here.Can he get by using 1/2" (vs. 3/4") square?Maybe:1-for starters make the framing--mitered with full, ground bevel welds, not the whiz-bang open end joints seen in the pic. Much stronger frame.2-use doubler plates at all support tube connections to the frames and the original assembly--to prevent tearing thru the wall of the tubing and distribute stress. The doubler plates are only welded along both sides--not across the ends of the plate, and thus the tubing's length.    If possible, position that bottom triangulating tube-brace right to the corner of your nicely mitered frame--not several inches above.3-really study the fit and mounting of those OEM mounting tabs, the bolts, hardened washers, etc.--that's usually where things crack and breakLast edited by dave powelson; 08-11-2008 at 08:25 PM.Reason: spellunBlackbird
Reply:Additionally, this mystery puck mount, needs to be studied, for exactly how and where it will mount into this steel frame.Blackbird