My girlfriend will be riding back to Kansas City from Phoenix on the back of my Strom. Since it's the longest bike trip she's ever taken, I want her to be able to relax.
First I took two 18 inch sections of 1 1/2 x 3/16 flat stock and, using an oxy acetylene torch, bent it at a bit over 90 degrees right in the middle. Then I cut three 4 1/2" cross bracings. After this I bent (using the torch again) the luggage tie down points from 3/16" Rod and 3/4" flat stock.
Then I arc welded it all together and polished out the welds and took the corners off the back to conform to the shape of the original rack. I was trying for a slightly more manufactured look. After this, I welded on all of the luggage tie down points.
Here's the welded rack mounted on the bike for test fitting.
I prefer to hang dry for a fresh clean scent. I coated the entire rack with bed liner. (My KLR tried to jump into the photo...)
Then I cut out the shape of the back pad using a scrap of plywood siding I had laying around. The wood will be screwed to the bracket then padded and upholstered.
Next week will be padding and upholstery. I'll update the post when that part is finished, probably will be next weekend before everything is complete.