I'd been wanting to try a real porteur-styled rack on my bike for a long time.
I liked the idea of a platform that sat close and low to the fork crown, allowing for larger and/or more oddly-shaped loads. But the cost of new, factory-made racks remains prohibitive, averaging over $150. Custom models start at around $200.
Inspired by a similar rack on a bike I'd seen several years ago, I decided to try making my own.
1. I obtained a canti-boss mini-rack cheap on craigslist ($18)
2. I mounted it on my bike. Then, I used hose clamps to install a miniature broiler grill (sans drip pan, about 13" x 9") that I'd found at Goodwill ($4)
3. Finally, I mounted a discarded rail from a very nice factory-made rack that I had scored at the CCC's Salvage Sunday for something like $0.50.
Additional hardware needed to put it all together -- hose clamps, L-braclets and various nuts a bolts -- came to another $6 and change.
Photos below show the basic assembly process.
After I'd installed the platform, I realized that carrying any load more than around 3 or 4 lbs. on a rack mounted on cantilever struts would break the rack. So to increase strength and triangulation, I installed additional full-length struts I'd salvaged from a WALD basket.
Hose clamps hold the platform securely to the mini-rack.
L-brackets (above) hold the guard rail securely. Front pair of bolts also secure the full-length Wald basket struts (bottom end incorporated with fender stay bolt, in fork eyelet.
Total cost of creating and assembling my porteur rack came to around $30 and change.
And it actually looks okay. My bag fits nicely in the rack, and with the addition of a couple of lashing straps it's sturdy enough to manage a short case of beer or a trio of growlers (something to keep in mind for summer barbecue season).
I'm quite pleased with how it turned out.