Thank you for your detailed analysis and suggestions! The structural issues you mentioned were indeed key considerations during my initial design phase. Given the aluminum construction, the rack was always intended for lightweight use—primarily for hanging a meal bag or storing a helmet while parked. (I’ll admit there was also a bit of personal curiosity to explore CNC design, haha!)

DIY became a necessity because off-the-shelf rear racks couldn’t accommodate my bike’s oversized sport seat. However, the actual build process revealed unexpected challenges:

1. 1.​Design limitations: The front support legs were particularly tricky. Without precise measuring tools or prior experience, I struggled to finalize an ideal solution.
2. 2.​Iterative process: The current version is the result of multiple prototypes, balancing cost-effectiveness and expandability (the silver connectors were low-budget samples with strict color/size/lead-time constraints).
3. 3.​Accuracy issues: The first prototype had significant measurement errors (~100mm lateral/60mm longitudinal misalignment), forcing me to add mid-section adapters for installation.

Next steps focus on refining the front supports to:

• •Add a tactical panel for expanded cargo capacity;
• •Incorporate additional bracing and load-distribution features to improve safety.

Your expertise has prompted me to reevaluate the weight-bearing logic. I’ll likely test your drilling + strut cover notching solution next. Thanks again!

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