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.

Don't often disagree with Oekmont, but I do this time. I don't consider that composites are the best way forward here. The inherent weakness is in the fastenings. Titanium is used in race cars and aircraft so perfectly suitable for your application, subject to choosing the correct grade.

I do agree, however, that the weight saving would be outweighed by the maintenance/repair problems in the field. I doubt that many backstreet workshops stock titanium filler rods or epoxy repair resin :-)