Like I said from the beginning I built this to ride, starting with a good long distance ride from Ohio to Alabama this week. I decided to build a sissy bar, but I built it to be fully removable so I do not have to run it all the time. This is purely for gear, not aesthetics. I started with some aluminum fill rod and got the bend and dimensions I wanted. I laid out the lines and bungs for bend points on a 1/4" sheet of steel and grabbed some 1/2" stainless steel rod.
A little ox-acetalene makes this job real easy!
You can see as I bent I also laid the wire form on top to make sure I was getting the bends just right. I cut the loop to length and tacked it to the stainless bungs bolted to the bike's rear frame rails
I made stainless gusset plates to attach to the second set of bungs to keep the bar vertical, and drilled holes in them for additional strapping points. I also cut and welded in two cross bars for rigidity and again additional points to strap my gear to.
I am really happy with how this all came out, and I have strapped gear to it and rode, it works great and with my pack strapped to it I can lean back and have some nice back support for long rides.