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Discussion Starter · #1 ·
I thought I'd share my experience and approach. I did a lot of research first and took the best (IMHO) of what I found.

The rack comes with a good rubber mount isolation kit, but I wanted a bit more protection to avoid cracking. Rather than order and wait for the star washers, I took fender washers and machined a nice radius on the outer diameter. All I did was to cinch the washer up on a long bolt and chuck it in my drill press. A little file action and I had a nice radius. I then painted the washers a nice gold color to contrast a bit with the pearl yellow. Under the fender washers went a neoprene rubber washer. I carefully measured and marked the two rear-most hole locations on masking tape. I put the rack as far forward as I could, only leaving a bit of clearance with the back rest to allow for a bit of movement when the upholstery is compressed by a passenger. I wanted to allow for a spoiler if I ever chose to add it.

Then I drilled and temporarily bolted in. I then marked the front two holes on masking tape and drilled them. Between the inner cover and the underside of the trunk lid, I made large filler washers of about two inches in diameter using bondo (car body filler) with saran wrap on one side as a release agent. I let it harden then re-drilled my four holes through the bondo. When I went to finally bolt the whole thing up with all the washers/spacers, unfortunately I found the left front hole was slightly off - I had to oval the hole out a bit to avoid too much stress on the cover by jamming the screw against the edge of the hole. The ovaling makes no difference with the fender washers, but I hate to know it's there.

I'll be doing the 1/4" tubing trick in the weather strip as soon as it's warm enough to work it through. Overall, I'm happy with the installation. It looks nice and with a good mechanical coupling with the inner cover, I think I'll be in a good situation to avoid load cracking; I'll be planning nothing but light weight, bulky clothing in the Kury bag I'll be using on the rack.

Rob
 

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rack install.....

Rob,
Sounds like you did pretty good on the install of the rack. You can always add the star washers at a later date. I did not add a rack on my yellow wing.I have the spoiler only.
I just simply toss the bulky stuff into my bushtec quantum, no problem with 26 cubic feet of storage space. Different strokes, ride safe.
JD'
:biker:
 

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I've been looking at my rack and trunk, hard to punch those holes in that plastic. Have no problem with putting the Utopia backrest into the seat. LOL
I thought about turning and polishing some stainless steel to do the same as the washers you painted up. Still have a problem drilling those holes.
Maybe best thing is to leave SWMBO (She Who Must Be Obeyed) at home so I can use that space for what may have gone on the rack.
Will run it by her next time I'm calling long distance.
 
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