Perun moto KTM 790/890 Billet rack - Small - design details

Our KTM 790/890 Billet rack - Small is meant for riders who prefer small and lightweight racks. KTM 790 and 890 Adventure bikes are very capable off-roaders and there are a lot of riders who don't carry much stuff off-road and they don't need larger racks, like our KTM 790/890 Billet rack - Large.

With this small rack, our goal was to keep the weight low and to place the rack very low, close to the plastics and flush with the stock seat. 

In order to achieve this we took a long way round - rack is CNC milled out of solid block of aluminum (actually aluminum-magnesium alloy).

We start with large piece of aluminum and we cut it on water jet. Each piece we get weight approx. 1400 gr.

And after almost twenty tool changes and some time in our Haas VF2SS with custom work holding, we get finished part that weights approx. 400 gr. 

We could make it even lighter, but we wanted to keep usable surface on reasonable level. So rack is small, but still very usable for 5-10 liter soft bags. Even 20 liter soft bag can be fitted nicely. More details about that HERE. 

Although lightweight, rack is still very strong. And it can be easily used as a grab handle, to maneuver the bike around the garage or to pick it up from the ground. 

But what makes this rack so different from the others is on the underside. 

We did a lot of CAD simulations and we removed all unnecessary material from the underside, to keep the weight low. In a way, I am sorry we are keeping these milled pockets hidden on the underside, but flat top surface will be much easier for maintenance and it is better suited for the soft luggage. 

And to keep the rack at an angle, flush with the stock seat, we milled 3D angled spacer platforms on the underside.

And appropriate angled countersunk holes on the top surface.

That is why we have to remove so much material. But the result is worth it. Rack is perfectly angled, very close to the tail (yet with more than enough clearance everywhere) and flush with the stock seat. 

And it looks so good. But that is subjective. Or not?