Luggage rack modification

I was at the test ride and came back to put the bike on the center stand. Motus published a video on how to put the bike on the stand by pulling the passenger footpeg mount. It was a bit odd since there is a handle like mount used for the side cases...a seemingly stout one at that based on the photos of the sub-frame-

This is how the side cases mount attaches to the bike:

 I removed my rear luggage rack mount that attaches to both bag mounts in a very quick/firm four bolt connection. I noticed that the left rack was 'loose' and attempted to snug up already tight fasteners. Pulling the assembly off the bike it became clear what the problem was.

An 8mm bolt goes through the side case mount to the sub-frame. The side case mount has a bushing welded into the tube of the mount...with two plug welds with not a lot of penetration. Most of the side case weight would be on these mounts. It didn't take much effort to punch the other side rack of it's plugs. I decided a modification was in order...not a factory approved modification, but one I would be happy with.

My planned solution is to replace the 1/4" thick bushing with a longer one.  McMaster.com #92415A135 to the rescue with a 1" long x 3/4"dia x 3/8" hole though the center. The idea will be to chamfer the bushing and TIG weld around the tube end with good penetration and a solid weld.

This will allow more weight to be supported by the tubing and not the welds. This will also give much more 'meat' of metal for the weld to stick.

First up, stripping the powder coat using JASCO paint and epoxy remover: The jug does not lie...15 minutes and the powder was coming off. 2 or 3 applications were required followed with some wire wheel finishing in the weld areas.

A case of beer for payment, the TIG work is done...

Matching up some powder coat samples... Looks like it is Powder Buy The Pound black texture 7-13% gloss matches the rear rack best.

Coated, out of the oven (375 for 10-12 minutes), and Givi parts back on. 
Ready to put back on the bike with longer hardware to deal with the longer bushings..

 Installed with rear rack and Wolfman peak tail bag.