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Old 09-16-2011, 03:16 PM   #1
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19H bumper mod

Hi All,

Here's some pics of the strengthening I had done to the bumper in order to carry the bike rack. I also did some other stuff like slide the bike rack all the way into the channel and drilled another hole for a regular 5/8 pin, then drilled again for the Thule anti-sway bolt. this way the rack doesn't stick out as far and I can add a locking pin if I want.

Hopefully you can see all the additional surface area my welder added for me. The original owner (yes, I got the 2011 used - short time; long story). Anyway he had welded just the short receiver channel on the bottom and tried to carry 2 adult bikes with it. they got 100 miles and it tore the original bumper brackets wide open out of the bumper.

I had that fixed and worked with my welder to make sure we had enough surface area and tied it into the frame in additional spots. I put a regular drawbar in there with a ball on it and stood on it and bounced up and down...that's 220 lbs bouncing on it and it didn't flex a bit. The welding cost me $90 - I gave him $120 to add a little tip because I think he did such a great job. The Thule rack I just bought today off Craigslist for $60.

oh ya, add $18.00 for the Milwaukee 5/8s reduced shank drill bit I needed for the holes in the rack and channel.

I have already tried and I can fold it down with the bikes on it and get it back up and pinned by myself as it will have to go down to open the rear bed. Also, I can see the 2 outside bikes from my onboard rear camera so we'll see how much movement if any there is down the road. It sure feels very solid...there is no movement in the channel with the pin and the bolt in.

Added a few more shots to show more surface area. All bolted on with 9 Grade 5 - 5/16 hardware.

Always open for questions.

Mark Fisk
Attached Thumbnails
BumperPaint.jpg   BikeRack.jpg   Channel2Frame.jpg   Pin&Bolt.jpg   BikesOn1.jpg  

BikesOn2.jpg   Bolt2FrameMiddle.jpg   BoltOriginal1Inside.jpg   BoltOriginalPlus1.jpg  
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Old 09-16-2011, 03:24 PM   #2
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Nice work Extremist. You are becoming a "mod" authority!
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Old 09-16-2011, 03:31 PM   #3
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Quote:
Originally Posted by Crabman View Post
Nice work Extremist. You are becoming a "mod" authority!
Thanks Crabman - labor of love...You should see my motorcycles!
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Old 09-16-2011, 06:22 PM   #4
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Mark,

Looks like a great mod that should hold up just fine traveling down the road, unlike the prior owners attempt.

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snip.....and pinned by myself as it will have to go down to open the rear bed.....snip
I would make one recommendation, and that's to replace the standard 'bent pin' with a straight one. The bent pins have a tendency to elongate the metal where the inner radius of the pin comes in contact with the metal (happens all the time on TV receivers).



The following pic shows what can happen (mild case):



If you can't find a standard straight pin/clip, you could go with a straight receiver lock like this (they do come in a couple of different diameters): http://www.campingworld.com/shopping...eceivers/56171

Bob
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Old 09-16-2011, 07:12 PM   #5
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Quote:
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Thanks Crabman - labor of love...You should see my motorcycles!
OK, let`s see `em! Pics?
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Old 09-16-2011, 10:32 PM   #6
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Very nice Mod EXTremist! Think I need to find a square bumper for mine now and start the Mods'.
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Old 09-17-2011, 07:24 AM   #7
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Thanks again Bob - I plan to get a straight locking pin...too bad it won't be keyed the same as my TT pin. That is my backup emergency (kids played toss the locking pin game while camping) pin.
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Old 09-17-2011, 07:33 AM   #8
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OK, let`s see `em! Pics?
Oh...poor babies have been totally neglected since I got the TT. I have 4 of them.

2011 Kawi Concours 1400 (black) with HIDs, Vario windscreen, 47 liter top case with lights (brake, turn etc), Two Brothers exhaust, Cox radiator guard, fender extender, wired for GPS and Smart phone and several other minor mods.
2008 BMW K1200S Tri-color has HIDs, Remus exhaust and a several other goodies to make it faster and more comfortable.
2007 Suzuki SV650S mostly setup for the track but still street legal. Has DOT race tires, custom front fork internals to my spec, Yosh pipe, PowerCommander III, and a custom rear shock from a ZX1400 for my 220lbs!
2010 Kawi Ninja250 Special edition with HIDs full Jardine exhaust, stage 3 Factory pro jet kit, and K&N pods in place of the air box.
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Old 09-17-2011, 08:08 AM   #9
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All,

I did add a ratcheting tiedown to this setup around the Thule up to the drop bed handles to take up the slack in the Thule pivot. I get it that the rack has to drop down but watching it on my rear cam while driving on a notorious hwy (100) here (on purpose) for "road-bucking" the rack just bounced around too much for me.

I will probably add some "soft ties" to those bed handles to avoid damage from the hooks but the strap is a must in my opinion.
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Old 09-17-2011, 08:52 AM   #10
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Mark great job/ engineering, I aasume you converted the "C" bumper into toilet paper, which is all it's good for. Larry
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