Installing the Rally Raid Soft luggage racks with a Nomadic rear rack [updated 6.3.2015]

Finally got a around installing the rack. For some reason I had decided that I wanted the whole rear of the bike matte black now that the bike would have the black racks to ruin the "lines". Childish I Know.

I bought a new black rear fender and painted it with rubber paint similar to Plastidip. The end result matches the tank surprisingly well.

Painted and unpainted black plastic side by side

RR provided spacers in place

The lower part mounted with RR provided hardware. I would prefer the 19 mm spacer to be much wider as there is space.

Installing a bolt that is too long  on the lower mounts will result in disaster

To avoid damage to the lower mounts, my plan to was to mount the lower ends using a large stainless steel washers that have a rubber "insert". This way the stress of the mounting bolt is divided to a larger area and the rubber may help absorb some of the vibrations. This may be a completely faulty logic, but I gave it a go anyway.

Stainless steel washers and a rubber mat with self adhesive back

self made "vibration damping" washers (holes not punched yet)

As I knew about the weak spot of the rack (the lower mounting points) beforehand 

( more here )  I had time to source the extra bolts and washers needed. The lower mounting holes need special attention, because using bolts that are too long will damage the rear swing. I used 50 mm long bolts, the RR provided 19 mm spacers and 3 washers + rubber washer.

The improved mounting solution

I added a third washer as the rubber flattened so much after tightening the bolt that the bolt was starting to protrude from the other side. It was only a couple of mm, but I wanted none of that. That yellow stuff is the adhesive from the rubber pushing out under pressure.

The final result looks sturdier to me

 

The Nomadic rack required the 3 small rear screws to be loosened as the RR bolts would not fit through otherwise.

My improved mounting plan is below, but I need to find the parts for that first

UPDATE [5.3.2015]

I accidentally found the missing hardware for the lower mounts. The local auto/bike parts store had a bag of "headlight mounting spacers" that have spacers almost exactly like the ones I was planning on having made. Had to buy two bags to get 4 spacers of the appropriate size, but still a big win. The spacers are chrome plated aluminum.

UPDATE [6.3.2015]

The final solution. I replaced the RR spacers with larger ones and secured the bolts with steel wire to prevent losing the hardware if the bolts come loose at some point. I'm done fiddling with the lower mounts. If they break they break.

The safety wiring needs to be sorted. This is not how it should look.