[Rainman]

Just doing some minor maintenance a month or so ago, I saw that the cross member that the Cyclerack bolts to was cracked. I finally got around to removing it today in preparations to get it welded this weekend. It cracked on both sides all the way through.



No big deal, I'll get it welded, just wanted to let you guys know so maybe you'll check yours as well. The bolts holding the rack on were tight, so I figured it cracked due to use and age.



Looking down from the rear of the bike.

Right side.

Left side.

Piece that broke.

 

[ronnydog]

[/quote]





Rainman, I put in a thick strap of metal bent to match the stock strap. Drill and tap, weld...done. Been there for 17 years.

 

[phelonius]

Perhaps if you had not been transporting that dead hipponocerous home from the hunt it might never have cracked.

 

[lizrdbrth]

These things could really use a rear frame loop.



Lotta`twisting goin' on back there with that mickeymouse sub-subframe arrangement.



Any of you hollow mod types done it?

 

[ronnydog]

I added a strap.

 

[Beewerks]

I'll have to check mine. I lift the back of my Tdub a lot with that rack so the cross member does get a lot of strain. Thanks for pointing it out!

 

[Rainman]

I'll have to check mine. I lift the back of my Tdub a lot with that rack so the cross member does get a lot of strain. Thanks for pointing it out!

I do that too! It makes for a great handle.

 

[flingwing1969]

I added a strap.

Great idea ronnydog - that piece of OEM lightened sheet metal isn't much of bracket for the way most of us are loading our T-Dubs for three-year expeditions.

 

[ronnydog]

Great idea ronnydog - that piece of OEM lightened sheet metal isn't much of bracket for the way most of us are loading our T-Dubs for three-year expeditions.

Thanks Flingwing, you are right about the loads! Are you comming to the ride at Panamint Springs Resort next month?



Ronnydog

 

[turborob]

I just noticed mine's done the same thing - doh!



Might be using that welder for the first time - wish me luck!

 

[Rainman]

I just noticed mine's done the same thing - doh!



Might be using that welder for the first time - wish me luck!

Bummer! I welded mine and then it broke again. I had to cut off the whole piece and weld on a thicker piece of metal. Its held up for a year now.

 

[Gerry]

Great follow-up on the first fix Rainman... Thanks. Gerry

 

[mrbracket]

Just thought I'd add an additional place to look for cracks on the rear end (no, not a butt crack!)...

Mine cracked on both of the turn signal mounts. This may not apply to the Cycleracks, not sure if they mount there, mine had a Yamaha rack on it when I got it. In any case, a good place to look for cracks....

 

[Tirebiter]

Thanks for showing that mrbracket. The turn signal and tail light mounting tabs are really thin. I think I'm going to take mine apart and reassemble with fender washers against them.



It looks like ronnydog's way of fixing/preventing the broken strap Rainman found is a good fix....maybe even adding gussets at the bends too (probably overkill). Anybody else have ideas?

 

[canyonlock]

I would braze that rather than weld it. silaca bronze, or nickle silver is remarkably strong and resistant to vibration and dis-simular alloy cracking. rw

 

[frog13]

I would have thought the cycle rack would have supported(stabilized) this area instead of crack.......since the rack also mounts forward?.

 

[PlacerLode]

With the design of the (rear) Cyclerack the front mounts are actually pulling upward and the rear mount is the fulcrum point holding not only the rack but anything placed on the rack is leveraging against that fulcrum point. I haven't seen the frame break but I have had the racks bracket crack and break the welds on the rack. Still it's the best rack out there because the other racks put weight on the ultra cheesy rear subframe that can barely support the tailight let alone cargo!



I should add the rack I saw that was broken was thoroughly abused and way overloaded (admittedly) by the guy I got it from. I've seen people break hammers so nothing surprise me

 

[frog13]

So, is the answer of not having your frame or rack,crack.....to not overload or abuse the rack?. Or,is welding involved for another type of support bracket(s)?. TIA

 

[PlacerLode]

So, is the answer of not having your frame or rack,crack.....to not overload or abuse the rack?. Or,is welding involved for another type of support bracket(s)?. TIA

I've only seen one cracked weld on a Cyclerack and that particular 2010 TW also had bent footpegs and serious dings under the frame from admitted overuse buy the owner (he showed me all this stuff before I acquired the bike)As I recall he said he found an old Jeep out in the forest and he hauled out differentials etc through rivers and streams full of boulders on the rack of the TW. I've had dozens of other TW's with Cycleracks as far back as 2001 and never saw any problems. Even the rack that was cracked sold the first day on Craigslist for $100 and the guy said he was happy to weld it up and repaint it and I'm sure it's still in use today!



So re cracks treat them like a bridge and cross them when you get to it

 

[PlacerLode]

I added a strap.

I'm loving this fix! Looks like a tank mechanic repaired this