I had made a rack to attach to my ktmduals rack on my '09, for camping expeditions, so when that got 'written-off' last July and I took delivery of its replacement, the 2015 650LT, it was in the 'planning' stage.
I added the Kawasaki rack (designed for the Kawi trunk) a few weeks back, then got to work.
FIRST - I ordered a piece of aluminum 20"W x 24"L, w/ two bends put in on their brake at the 24" end. First bend was 4" from the end, at 30 degrees, w/ another break at 90 degrees 1" from the same end. Here's a pic:
As I wanted it mounted more forward than I'd done on the '09, I thought it would be a good idea to be able to remove the seat to get at the battery w/ the rack still attached, so next I figured WHERE and HOW to make the cut, and marked it onto the aluminum, PLUS about 1/2" more.
Then I cut it out w/ a jig-saw, and smoothed the edge.
Next up was to match the holes in the Kawi rack, to attach this one to,
then set-up my drill press, and 'bore' the four holes.
On the '09 rack I'd drilled many holes around the whole periphery for the tie-downs, but this time I decided to use some 5/16" "eye-bolts" that previously were used in pulling Chev V8 engines, so I drilled three holes across the rear 90 degree pat, as well as two per side up front. (I use ROK Straps, and did NOT want there to be any chance that a sharp-edge in a drilled hole would cut them!)
Additionally I wanted the bolts that hold MY rack to the Kawi rack to be metric, button-head socket stainless ones c/w locknuts and washers, to avoid holes thru my waterproof canoe-bags holding my gear...!
Then, between adjacent eye-bolts on the rear, I added some red reflective tape.
Total cost (not including my time, or the eye-bolts and tape...
) was $45 Canadian. HOPEFULLY it'll work as well as the '09 rack did, tho' it won't be as FAR back...!