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Polaris General Bed Rack

Bigblue&Goldie

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Joined
Mar 12, 2009
Messages
10,734
Location
AZ
A good friend of mine has been wanting a way to mount a spare tire and some fuel to his General. He had been looking at what was available on the market and wasn't overly excited about any of them, or their prices. I'm always looking to improve my skills, so I told him I'd do one up for him based on how I'd like it.

Goals:
-Must be easily removable
-No rattles
-Lightweight
-Fit with the cooler and tools box he carries
-Be non-intrusive

I came up with a design that mounts using the bed rail pockets and expanding plugs. No tools required to remove the rack, and is easily done by yourself. The rack carries a tire via a 3 point strap and a water/gas Rotopax. When a spare isn't needed, the rack can be used to carry larger items as it's a flat surface with tie down points. Went with 1.50", .095 HREW to keep cost down, but maintain strength. Feet are .1875 flat stock.

Rotopax mounts; bought 4" circle cut outs, drilled the bolt pattern, made the tube tabs.
NBQpN6j.jpg

How the mount to the rack.
IJihThi.jpg
 
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Bigblue&Goldie

Well-known member
Joined
Mar 12, 2009
Messages
10,734
Location
AZ
Tacked together, showing the stuff he generally carries.
DGRTlq6.jpg

Cans are at an angle to match the cage. They aren't even visible in the mirrors as the bed angles in at the tailgate end.
Cc06oXZ.jpg
 
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Bigblue&Goldie

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Joined
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Welded up.
KFo18kL.jpg


Single pass on the tubing (.095 HREW), double pass on the tie down tabs (purchased from SDHQ) as they were .250.
4YhOO0O.jpg
 
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Bigblue&Goldie

Well-known member
Joined
Mar 12, 2009
Messages
10,734
Location
AZ
Tire mounted.
nKKWWrn.jpg

dw3Bwxz.jpg


One last test fit to make sure nothing went wonky during weld out, and it's off to powdercoat. I'll get a pic on the car in a couple of weeks when it's coated as I don't have it right now.
 
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