The problem is the mount locations, they are to close together.

Need to get this style rack:

http://cgi.ebay.com/ebaymotors/Harle...Q5fAccessories

This puts the front mount up by the shock, spreds out the load and doesnt rattle.

 

That is exactly like the original detachable rack HD sold when they introduced that line of accessories. I bought one in 95 for my RK to put a tourpack on, and still have it today on my 08 SG.

 

I will be keeping and eye on this as well. I just installed a chopped pack using Gilbos mounts and the rack from Milwaukee baggers. The two together were an extremely tight fit to begin with, I had to "convince" the rack to go on.

 

https://www.hdforums.com/forum/touri...part-deux.html

 

make em outa stainless. its harder and wont rust. Mine are worn as well and when I get my *** in gear I'll fab some up too. Or I'll buy em if the price is right but my labor is free for me so it will prob be the cheap way out.

 

I didn't go with stainless for a couple of reasons:
1) No tooling on hand to machine it
2) There has to be some play to be able to mount the rack, so it will rattle

I ended up using Delrin - so far, it's working great.

 

teachu2 - glad to hear you are working for a solution. I have had this problem for more than a year now and have rotated my aluminum bushing from Gilbos after he sent me a slightly larger set as well, I have no rotation left. I was looking at getting a new rack frame as thought maybe slots were slightly oversized from the factory, but ~$120 from Zanottis is a bit pricey for a chance of it not solving the problem. I was going to take the tourpack off tomorrow night to look at the situation, but now came across this post. Looks like a fix is proving difficult.

 

I got used docking hardware for my Road King in order to put a quick detach tourpak on it and noticed that the plastic bushings were cracked badly. I pulled them off and replaced them with automotive 3/8" rubber gasoline line. I cut the gas line to the same width as the bushings, then put a slit in it and put it over the docking hardware with the slit facing forward. I then spread a very light coat of dielectric grease on the rubber (the same stuff you put on your windshield bushings). The fit is perfect. The bracket slides over with a slight push and they suck right on there. No vibration or rattling. I figure when the gas line wears out I will just do the same thing over. Cost was practically free.

I haven't had any problems with the rubber bushings coming off when I remove the tourpak but when I replace them I'm thinking I might put a little glue on the anyway. I'll most likely use "Goop". Stuff works on nearly any material and is perfect for gluing dissimilar things.

 

Where are you in NoCal?

 

In Sacramento