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DIY Grab rail?

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A100man
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PostPosted: 14:20 - 19 Apr 2022    Post subject: DIY Grab rail? Reply with quote

Hi All

Took a pillion on the XJ 550 this weekend and it was obvious a grab rail would be handy for no other reason than to prevent my passenger sliding forward and forcing my bollocks into the tank.

For this model however there are none easily available - ones for the 'Maxim' cruiser variant do not fit so I figured it shouldn't be that hard to make one.. however while I have a plumber's pipe bender the compound curves required look tricky. So, if anyone has some fabrication tips that would be appreciated. The rare factory option is pictured below but I don't need to it to look as shiney as that on my old dog..

PS I don't think it needs to be made from round tube but that would be best.

PPS I have a hobby MIG that should be up to welding up brackets

https://assets.catawiki.nl/assets/2020/1/3/a/c/b/acbb6e9d-5c71-4637-bb61-983f8de60d24.jpg
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c_dug
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PostPosted: 15:05 - 19 Apr 2022    Post subject: Reply with quote

I hate bending pipe. Neatly bending a single run is difficult enough, but getting two sides to look near identical is a complete mysterious black magic to me.

So, personally if I wanted to do the same I would be looking for something of a reasonably close fit to modify, rather than trying to start from scratch.

For example just as a quick google suggests the maxim rail might be made to work with some adaptations:

https://xjbikes.com/forums/threads/550-maxim-grab-rail-on-a-seca.98801/
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WD Forte
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PostPosted: 15:17 - 19 Apr 2022    Post subject: Reply with quote

May we suggest Sir wears a well cushioned codpeice ?
We cater for all tastes and they come in a range of attractive colours

The 'Violator' model made from brass with lambs wool padding is very popular at the moment


https://external-content.duckduckgo.com/iu/?u=https%3A%2F%2Ftse2.mm.bing.net%2Fth%3Fid%3DOIP.0WTKMNYOn_UUIH2jC3b8sgHaGb%26pid%3DApi&f=1
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c_dug
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PostPosted: 15:20 - 19 Apr 2022    Post subject: Reply with quote

c_dug wrote:
https://xjbikes.com/forums/threads/550-maxim-grab-rail-on-a-seca.98801/


In fact it looks like you appear in the very thread I sent you Laughing

Or you have a namesake, one or the other.
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A100man
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PostPosted: 16:00 - 19 Apr 2022    Post subject: Reply with quote

c_dug wrote:
c_dug wrote:
https://xjbikes.com/forums/threads/550-maxim-grab-rail-on-a-seca.98801/


In fact it looks like you appear in the very thread I sent you Laughing



Yeah - took me a while to get around to it right?
After all the cut and shut involved I thought it might be easier to build from scratch than modify..

..I may have been wrong though. At least there are some Maxim ones for sale here - which is odd given it's an import.
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A100man
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PostPosted: 16:01 - 19 Apr 2022    Post subject: Reply with quote

WD Forte wrote:
May we suggest Sir wears a well cushioned codpeice ?
We cater for all tastes and they come in a range of attractive colours

The 'Violator' model made from brass with lambs wool padding is very popular at the moment


https://external-content.duckduckgo.com/iu/?u=https%3A%2F%2Ftse2.mm.bing.net%2Fth%3Fid%3DOIP.0WTKMNYOn_UUIH2jC3b8sgHaGb%26pid%3DApi&f=1


My word.. Shocked
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stinkwheel
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PostPosted: 17:12 - 19 Apr 2022    Post subject: Reply with quote

You could try cold setting the bends on a wooden form using the pipe filled with sand technique. Work out the spring-back on the bends first and make the curves on the form more acute by that much. Cable tie and clamp it to the form as you go.

It's only a few bends. I'd do the top one first so you have a huge long U-shape then the side ones then the two little tweaks at the end. Leave it over-long and cut the ends off.

I managed to make an acceptable rectangle this way on the first attempt for a luggage rack. I didn't allow for spring-back which left me with a degree of fenagling to do afterwards. I'd use a form with two 80 degree angles next time and do each end seperately.
https://lh3.googleusercontent.com/pw/AM-JKLVlJEPOeH5x4Bg5-6eBLgwPcIJByxsjxgfs4IwV18cScRrVIaF4Y385CRqDwLczpImZV4ht_eahx4LZcmV42htWcxjHf-s4hz6KnOzN7PujspRLiHmk1CtSDq7hnORThW2nOKgC6o5JPPvDRAAp4xbA=w1378-h775-no

https://lh3.googleusercontent.com/pw/AM-JKLUbg1biypIWXdi6IbBrPCQem8fEF64viLxXlb3nH60th0dxpLGs-xzqbHwBHUm_g3GKXAAKFO1ndY1ALpb1mb8F4GUkh4mywHpULh18yHbchPUwkHprAN-mcY0b9EVcVn9HKC2ihFBmuWsJO6TCpsgy=w1378-h775-no

https://lh3.googleusercontent.com/pw/AM-JKLURLG9oV8pnsPN2TgE5YEfrf-Meyt9aSu5TNLPY3Q09WzBcxPbmtgxCp6VswXKg3mx6qZMgQJjW9vF3Ph2CNal8qG3doh7zmD6p4sBGRsX-2OnsVyOljQ6B4imOMnBmNPdfoknSyZJt1tTc6bzNUg45=w1378-h775-no

That's 1/2" x 16g steel tube. Might want to bump it to 3/4 or 7/8" for a grab rail. The thinner wall is plenty strong enough, I can lift the back of the bike up by it.
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stinkwheel
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PostPosted: 17:16 - 19 Apr 2022    Post subject: Reply with quote

I've also seen someone make up a whole luggage and pannier rack using malleable iron plumbing fittings and steel pipe.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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A100man
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PostPosted: 20:52 - 19 Apr 2022    Post subject: Reply with quote

stinkwheel wrote:
You could try cold setting the bends on a wooden form using the pipe filled with sand technique. Work out the spring-back on the bends first and make the curves on the form more acute by that much. Cable tie and clamp it to the form as you go.

It's only a few bends. I'd do the top one first so you have a huge long U-shape then the side ones then the two little tweaks at the end. Leave it over-long and cut the ends off.

I managed to make an acceptable rectangle this way on the first attempt for a luggage rack. I didn't allow for spring-back which left me with a degree of fenagling to do afterwards. I'd use a form with two 80 degree angles next time and do each end seperately.
https://lh3.googleusercontent.com/pw/AM-JKLVlJEPOeH5x4Bg5-6eBLgwPcIJByxsjxgfs4IwV18cScRrVIaF4Y385CRqDwLczpImZV4ht_eahx4LZcmV42htWcxjHf-s4hz6KnOzN7PujspRLiHmk1CtSDq7hnORThW2nOKgC6o5JPPvDRAAp4xbA=w1378-h775-no

https://lh3.googleusercontent.com/pw/AM-JKLUbg1biypIWXdi6IbBrPCQem8fEF64viLxXlb3nH60th0dxpLGs-xzqbHwBHUm_g3GKXAAKFO1ndY1ALpb1mb8F4GUkh4mywHpULh18yHbchPUwkHprAN-mcY0b9EVcVn9HKC2ihFBmuWsJO6TCpsgy=w1378-h775-no

https://lh3.googleusercontent.com/pw/AM-JKLURLG9oV8pnsPN2TgE5YEfrf-Meyt9aSu5TNLPY3Q09WzBcxPbmtgxCp6VswXKg3mx6qZMgQJjW9vF3Ph2CNal8qG3doh7zmD6p4sBGRsX-2OnsVyOljQ6B4imOMnBmNPdfoknSyZJt1tTc6bzNUg45=w1378-h775-no

That's 1/2" x 16g steel tube. Might want to bump it to 3/4 or 7/8" for a grab rail. The thinner wall is plenty strong enough, I can lift the back of the bike up by it.


Thanks for the tips, interesting..16g 1.5 mm steel must be tough to bend by hand though (but easier to weld than thinner stuff).. not tried the sand method before only bent copper tube on the Hilmore before and 22mm is still a bit of a grunt.
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WD Forte
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PostPosted: 21:35 - 19 Apr 2022    Post subject: Reply with quote

Interesting
Food for thought here
I want make up a rack to bolt my Givi top box base plate to
on the scooty grab rail

Been mulling over options and what material to buy
and kinda going in a square section tube direction
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stinkwheel
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PostPosted: 21:51 - 19 Apr 2022    Post subject: Reply with quote

A100man wrote:

Thanks for the tips, interesting..16g 1.5 mm steel must be tough to bend by hand though (but easier to weld than thinner stuff).. not tried the sand method before only bent copper tube on the Hilmore before and 22mm is still a bit of a grunt.


Sorry. My mistake. I checked my ebay emails and it was 18g x 1/2" ERW steel tube (1.22mm). Didn't take a lot of bending, I mean, you knew you were doing it but once it was started, it curled over nicely and progressively.

I got round the blowing holes in it with a welder issue by brazing it. Done a 10 day tour of the Picos and a Dragon rally with it fully loaded so far and it's holding up well. I was a bit uncertain about flex in the front stays but I put a slight lengthwise bend in them and it firmed them up a treat.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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Bhud
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PostPosted: 23:33 - 19 Apr 2022    Post subject: Reply with quote

The aesthetics would be the only problem. It would work but your bike would look wrong.

Might be worth picking up a random big-4 1970s/1980s grab rail from Ebay, cutting it and welding it back up with slugs, so that you have all the bends in the right sort of place.
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