Hello all i just finished a tour around the world on this motorcycle. I want to replace things and make this bike lighter overall. I want to start with the rack and work my way later to other projects on this bike.

I want to make a side pannier rack. I already have a custom made one but its steel and heavy.

The characteristics I am looking for in this project are: Great in tension(pulling on rack), impact resistance, abrasion resistance and lightweight 

this is a mock up using MS paint along with a picture included of my motorcycle with the steel pannier rack



I am thinking of getting it in 10mm thickness
https://www.easycomposites.co.uk/rigid-foams/easycell75g-infusion-grooved-closed-cell-pvc-foam-core.html

shape up the mock up in my MS paint drawing with this easycell75G, connect pieces with glue, sand around the edges to get it into circular/tube shape. 

then cover it all with 1 layer of Kevlar, 1 layer of 3D core and final outlayer of Carbon 2/2 twill 200g

Around the bolt plates in the picture, I will reinforce it with 1x small piece kevlar around the bolt hole and 2 extra layers of carbon fiber. So when bike crashes, the bolted joints to the frame of the motorcycle doesnt snap easily.

What do you think? can i get feedback on this plan. Maybe I can use some other core?, use different layer?

Thank you ,

- BkADV

i am fine with a total thickness of around 0.75 inches.