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Discussion Starter #1 (Edited)
I've been thinking about making my own for years and finally got a start on it this winter. I plan on having it haul a set of saddle bags and top box. I really have no good reason for it as I don't do any long trips (yet) but maybe that'll be in the future.

Started with a spare SV wheel I've had. Sourced the swingarm and lightly twisted DL1000 subframe from Ebay

Seeing how bags might fit

Waterjet cut swingarm pivot brackets

Test fitting with a shock and center stand from an old Suzuki FA 50 moped

Added some cross bracing to stiffen things up

Moped shock wasn't going to be stiff enough so I fitted one from an 81 GS750

So far, that's what I've got done. I'm able to get good frame tubing and try different shocks because my father has a lot of parts bikes left over from when he owned a dealership up to the early 80s. I've got a top box on the way and have sourced one factory bag so far. Once I find another bag and racks, I'll be able to do a lot more work. Next big step is attaching it to the bike. I'm pretty sure I'm going to use the bike's axle and my main point.
 

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I've been thinking about making my own for years and finally got a start on it this winter. I plan on having it haul a set of saddle bags and top box. I really have no good reason for it as I don't do any long trips (yet) but maybe that'll be in the future.

Started with a spare SV wheel I've had. Sourced the swingarm are lightly twisted DL1000 subframe from Ebay

Seeing how bags might fit

Waterjet cut swingarm pivot brackets

Test fitting with a shock and center stand from an old Suzuki FA 50 moped

Added some cross bracing to stiffen things up

Moped shock wasn't going to be stiff enough so I fitted one from an 81 GS750

So far, that's what I've got done. I'm able to get good frame tubing and try different shocks because my father has a lot of parts bikes left over from when he owned a dealership up to the early 80s. I've got a top box on the way and have sourced one factory bag so far. Once I find another bag and racks, I'll be able to do a lot more work. Next big step is attaching it to the bike. I'm pretty sure I'm going to use the bike's axle and my main point.
Nice start!!! looking forward to see completed trailer!
 

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I am so impressed with your start.

If you haven't already check this thread out. Ultra Light Wieght Trailer Project - Data and Experience Welcome

Here was SKS idea. Yours is looking pretty darn good.



I am saving this thread as a favorite and will follow your progress. Very impressive!

Also, check out surge brakes. I think you could easily make one for the trailer so the disc brake becomes functional.

That is a unique placement of the weight, suspension, and pivot point. I haven't wrapped my head around it yet, but at first glance it looks like it might work. Have you done the math or created a test jig to check the weight vs spring and pivot?
 

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Very cool! Just a question, but would the GS shock not be too heavy duty for your needs, as I would imagine that a 'softer' shock would not allow the back to 'hop' and so cause a tugging effect on the towing vehicle?
I also thought a smaller wheel or at least one that was narrower (perhaps a front one) would be better for drag, again, just throwing questions out at you. I'm very keen to see the finished product.
 

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Discussion Starter #7
The GS shock isn't going to work. :( It has a too light spring or maybe blown; either way, when I tried the racks and bags from my bike, it squatted way too much. I'll just have to keep digging through my father's stash. I tried one from my SV but it's much too stiff. I think I'll be moving everything forward 4-6" regardless of what I find to bring the weight to the front, it's back heavy now.

 

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Discussion Starter #8
Found different sets of damaged bags and made two good ones out of them... still looking for racks though :( I'm going to try a shock from a 2000 GSXR 600, I think it'll be the right rate.
 

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Discussion Starter #11
I got an OEM rack and trunk from a guy on ADV rider, did some cutting and welding to move it forward a bit to be flush with the fender, I'll get a new shot of it tonight maybe. Hoping to win a set of side racks on Ebay. My plan is to tow it down to the eastern rally.
 

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Discussion Starter #14
Nothing major to report yet. I did get a 99 GSXR600 shock and it'll work perfect. I have to change the upper mount for it as it's a bit longer. Still looking for OEM racks or at least the mounting hardware, i can make the frames easy enough.
 

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I will start planning my new trailer after I get back from the eastern gathering. I hope to use it for the western gathering in July.

My basic overall theme will be to mimic the bike as much as possible much like you are doing, but I'll probably use pelican cases on the bike and trailer.

I just love this stuff.
 

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Discussion Starter #16
Progress today... I figured out how to mount the GSXR shock.. it's a bit different but the spring rate is perfect. I utilized an old ATV rack and some scrap pieces of bent frame tube. This gives it a nice platform to strap anything down too. I'm still searching the world for a cheap set of OEM side racks and have come up empty so far :(


 

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Just a thought. Another option would be to hard mount the bags to a DIY frame.

I did this on my Wee. I had SW Motech removable racks with Pelican cases hard bolted to the removable racks. However, once installed I didn't remove them (not even once) until it was time to sell the bike. Using bag liners was much easier than removing the bags and taking them into the motel rooms.

You have good metal skills, so it would be faster and MUCH cheaper to make your own frame and hard mount the luggage.
 

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Discussion Starter #18
Advice taken.. hopefully 1/2" square is strong enough. I have more bracing once I get the other side tacked on.
 

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1/2 inch square can be strong enough if you have good wall thickness. Possibly more important is using strong shapes.

Triangles are better than squares and you seem to be doing a good job at that. A flat sheet properly fastened across a square makes two triangles.

Most of the aftermarket pannier racks have a brace running between the two racks from behind the wheel.



 

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Discussion Starter #20 (Edited)
Side case mount success! It was pretty difficult to match the angles on both sides and get it to be symmetrical since the bags are different widths but I think I got it pretty good. It seems like it'll be strong enough as long as I'm not hauling anything super heavy in them. All joints are completely welded so now all I have to do is figure out the hitch. A bonus is I don't have to drill holes in the cases. Amazingly, sprocket carrier bolts fit perfectly. I'm going to weld those bolts to the frame and probably just use a strap in the handles instead of fabricating a locking loop of some kind.

 
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