Front Rack

Build

For exact dimensions, you can use a soft metal and form design first
- Any soft copper/thin steel wire
Length: roughly 80 cm or 2.5ft
- To be safe, get a 3 ft steel pole
Diameter: 6mm, although 8mm can be used
- Kelly's saddle mount is 6mm ~1/4in
Material: Stainless steel (won't corrode in water)
- 304 stainless steel
- Cheaper Alternative: Galvanized steel (zinc coating will rust but protect steel)
  - However, if dinked, steel can rust underneath
- SS - Tacoma screw - $13
- SS - Threaded rod Home Depot - $8
- Zinc Plated, Home Depot - $6
- Online Metals, $5 ss rod, free cut and pickup :)
Clamps: 1/4in Wire Rope Clips, 2pc - Harbor Freight - $4
- NOTE: Most standard bike saddle rails have a diameter of 7 mm.
- Or Ace hardware Wire Rope - $7
- Mcmaster - $1
- Aliexpress - $1.75
- Amazon - 40/$20 or 12/$7.50
- Tacoma Screw - $8
- Granger - $10 each
Instructional video: YTB - DIY saddle bag support
- He says 11kg/20lbs is limit bacause bends too much
- Recommends to mount it to seatpost
Heat bending: locally heated with a torch to make bending easir
- Discolors it (rainbow/blue scale).
- Reduces corrosion resistance in the heat-affected zone
- Can re-passivate or pickle it afterward
- UNECESSARY
Bending: bend radius ≥ 2× diameter (so ~12–16 mm)