I carefully studied all data I got from test rack on my bike, from my riding buddies and from fellow riders across the world, and I implemented lot of improvements in new design.
Priority was to keep functionality of "old" rack, but also to improve strength of the rack and to make it more rackless bags friendly. Also, I implemented new manufacturing process, so edges are chamfered by machine and powder coating is much better.
I ran various tests on CAD model, and made more then few prototypes. Now pre-production model is ready and I am very, very happy with the result.
Here are few pictures of new rack - Perun moto KTM 690 Enduro Luggage rack SD.
Top part of the rack
It is redesigned, with wider "legs", smoother lines and new slots. Low profile and overall dimensions are kept. "Old" Extension plates are compatible with new rack. Also, compatibility with various pannier racks is unchanged. There are three 8 mm holes for mounting GoPro cameras or similar stuff on RAM mounts. Holes for optional extension plate are countersunk, so different clips for reckless bags can be bolted below the rack, keeping top surface flat (something like this, but with countersunk bolts). There are front and rear center slots, for rackless bags like Mosko moto Reckless line. Rotopax mount holes are still here.
Thicker material is used - 6 mm aluminum (AlMg3). It is cut on water jet. Edges are then chamfered on manual chamfering machine and sanded, so there are absolutely no sharp edges on the rack. Very healthy work environment for straps. Pre-production model is powder coated to black. I applied new powder coating process involving heating aluminum prior to powder coating and results are great. I planned to anodize production models, but now I am not so sure - new powder coating process gives very nice, smooth surface and I really like it. Bend angle is slightly different than on "old" model. Also, new bending process is used - it is bent with special punch with a radius, keeping it strong, yet enabling slots to be made near the bend line.
Bottom part of the rack
Bottom part, or bracket, is completely redesigned. It is much stronger than on previous model. It bolts to top part of the rack on four points. Also, bend angle is slightly different, again in order to improve strength. It is made of 5 mm aluminum (Almg3).
New countersunk aluminum washers and countersunk steel bolts are used. Bottom surface of new washers is much larger then on bolts used on previous model, which significantly reduces stress near the bolts. Spacers are larger in diameter, for same reasons.
I made 20 pieces of pre-production model and it is offered for sale, with reduced promotional price. Link to product page is here. Pre-production model is fully functional and finished product. Differences between pre-production and production model, if there will be any, will be minor. As mentioned above, I planned to anodize production model, but now I am not so sure - maybe production model will also be powder coated.