[richlandrick]

Check this out. Not the same model V-Strom.

Can you post a pic of the rack you have and want to convert?

 

[richlandrick]

It's more likely that foot print needed for their standard mount required more real estate.

Yes, I thought you were trying adapt the Givi to the factory resin rack. To do what you want I would create an intermediary plate between the Givi rack and the factory rack. Which appears to be what you had in mind. The front bolts on the factory rack carry the stress to the rear frame. I've written and deleted a bunch of how I might go bout it after realizing you probably have this figured out.

 

[richlandrick]

The three way to make something stronger are use more material, use a stronger material, or use a stronger shape. Those bends at the edges of the aftermarket 1/8 plate add strength. 3/16ths inch of any aluminum alloy you are likely to come across is going to be fine though. Be sure to spread the force at the back where it mounts to the factory rack using sandwiching plates to spread the force transferred to the resin rack. You probably knew that though.

 

[richlandrick]

Countersink for bolt head is called a recess, as in recessed hole.

I have often thought this kind of thing would make for a great community project.

 

[richlandrick]

Most countersunk bolts use a 45 degree head angle. Countersinks are available in a variety of head angles, but they all need to be used at low rpm to get a smooth finish.

The DL650 can be an excellent two-up sport touring machine with minor modification. Just stiffer springs front and rear, with rear rebound run completely full and then back off a 1/4 turn and fork brace made a hug difference for us. I combination transformed the bike.

Of course the seat becomes limiting, but a seat concepts seat kit will fix that.