Converting rear rack to seat

david3921 · 03-05-2017, 08:03 PM

I bought a pair of TaoTaos last year, A Rhino for me and a 125D for my 7 year old grandson. His little brother is almost 4 and I needed a way for the little one to come along for rides. I bought a MadDog seat off of Amazon on sale based on a recommendation from someone here (I forget who). Coleman sells a seat just like it for about half of what the MDs are going for now. The seat didn't fit well, however, as the rear rack has side and back lips that are in the way. Below are pictures of what I had to do to make it fit. Basiclly, I took off the plastic cover and then cut off all of the tubing that created the lip. I then bent some electrical conduit, making it large enough to support the seat. I then cut and welded support pieces that connected the original frame to the new one. After cleaning it up with a grinder and wire brush, I painted it textured black to match, let it cure out in the sun, and bolted it back together.

A couple notes on working with the conduit. First, safety. The conduit is plated and will give off dangerous gases when welded. The plating can be removed with muriatic (hydrochloric) acid. I always have some in my garage as it's great for removing rust. I placed the support pieces in a plastic container and slowly poured the acid in. I poured the acid back out when the reaction stopped. I brushed acid on the frame where I was going to weld with rags underneath to catch the drips.The second thing of note is that I didn't have a long enough piece of conduit to make the outside of the frame. I spliced two pieces together using 5/8" threaded rod and pop rivets. I found from another project I did that 5/8" rod will fit inside the conduit pretty tight. Once I got the ends together, I drilled some 1/8" holes through the conduit and rod, and then attached it all together using 4 rivets.

After it was all together, I rigged up a seat belt for the young one so he couldn't fall off. It worked but I want to come up with something better this year.

Darth Racer · 03-05-2017, 08:50 PM

Nice job on the new pipes and welds.. Finish product looks stock!!

david3921 · 03-05-2017, 10:41 PM

Thanks Darth. I used a HF bender and welder (cooking with gas) to get it done. I'll get up a pic with the seat on the ATV.

david3921 · 03-06-2017, 10:53 PM

Below is what it looks like installed. I bought a sheet of 1/2" plywood to put on top of the rack in case the seat proves too lumpy from the bars but so far, so good.

**JerryHawk250** · 03-07-2017, 11:48 AM

Nice job

I though about doing something similar for my Coolster 150. Thanks for sharing.

2LZ · 03-07-2017, 12:53 PM

Nice work! The welding thing has always had me buffaloed. I can stick two pieces of metal together in a very ugly fashion, but I envy this kind of stuff.

BlackBike · 03-07-2017, 06:33 PM

Great job, can a motorcycle engine crash guard be fashioned out of this conduct material. Practical? Would think it would be good for its light-weight properties.

david3921 · 03-07-2017, 07:13 PM

Thanks guys. The little one is super happy he can ride with his papa. I wouldn't hesitate on using the conduit for guarding. The 3/4" stuff almost matches the tubing that most use for racks. You can get it with thicker walls also.

FLASHLIGHTBOY · 03-16-2017, 02:01 PM

the seat and rack looks great.... but I no one sits there as it is unsafe.( hate to sound like a doubter) but those racks are not made for much weight... and it could cause the atv to tip over... it might be good for a light kid.. or to sit back when you are resting on the trail... .. It is just a thing to think about.. good ob on it as I say

david3921 · 03-31-2017, 08:09 PM

Quote:

Originally Posted by FLASHLIGHTBOY

the seat and rack looks great.... but I no one sits there as it is unsafe.( hate to sound like a doubter) but those racks are not made for much weight... and it could cause the atv to tip over... it might be good for a light kid.. or to sit back when you are resting on the trail... .. It is just a thing to think about.. good ob on it as I say

Thanks. He's 3 1/2 so not too worried yet. I do plan on beefing up the supports when the weather gets better.

Slaphappy · 03-31-2017, 10:54 PM

Man that looks good. Is there a way to strap the little guy in? Seems like a good bump might catapult him over the neighbors fence.

03-05-2017, 08:03 PM	#1
david3921 Join Date: Feb 2009 Location: Michigan Posts: 1,043	Converting rear rack to seat I bought a pair of TaoTaos last year, A Rhino for me and a 125D for my 7 year old grandson. His little brother is almost 4 and I needed a way for the little one to come along for rides. I bought a MadDog seat off of Amazon on sale based on a recommendation from someone here (I forget who). Coleman sells a seat just like it for about half of what the MDs are going for now. The seat didn't fit well, however, as the rear rack has side and back lips that are in the way. Below are pictures of what I had to do to make it fit. Basiclly, I took off the plastic cover and then cut off all of the tubing that created the lip. I then bent some electrical conduit, making it large enough to support the seat. I then cut and welded support pieces that connected the original frame to the new one. After cleaning it up with a grinder and wire brush, I painted it textured black to match, let it cure out in the sun, and bolted it back together. A couple notes on working with the conduit. First, safety. The conduit is plated and will give off dangerous gases when welded. The plating can be removed with muriatic (hydrochloric) acid. I always have some in my garage as it's great for removing rust. I placed the support pieces in a plastic container and slowly poured the acid in. I poured the acid back out when the reaction stopped. I brushed acid on the frame where I was going to weld with rags underneath to catch the drips.The second thing of note is that I didn't have a long enough piece of conduit to make the outside of the frame. I spliced two pieces together using 5/8" threaded rod and pop rivets. I found from another project I did that 5/8" rod will fit inside the conduit pretty tight. Once I got the ends together, I drilled some 1/8" holes through the conduit and rod, and then attached it all together using 4 rivets. After it was all together, I rigged up a seat belt for the young one so he couldn't fall off. It worked but I want to come up with something better this year. __________________ 2012 Kawasaki Versys 1984 Honda Magna V65 2016 Rhino 250 2016 Tao Tao 125D
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03-05-2017, 10:41 PM	#3
david3921 Join Date: Feb 2009 Location: Michigan Posts: 1,043	Thanks Darth. I used a HF bender and welder (cooking with gas) to get it done. I'll get up a pic with the seat on the ATV. __________________ 2012 Kawasaki Versys 1984 Honda Magna V65 2016 Rhino 250 2016 Tao Tao 125D
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03-06-2017, 10:53 PM	#4
david3921 Join Date: Feb 2009 Location: Michigan Posts: 1,043	Below is what it looks like installed. I bought a sheet of 1/2" plywood to put on top of the rack in case the seat proves too lumpy from the bars but so far, so good. __________________ 2012 Kawasaki Versys 1984 Honda Magna V65 2016 Rhino 250 2016 Tao Tao 125D
	3

03-07-2017, 11:48 AM	#5
JerryHawk250 Moderator Join Date: Oct 2016 Location: Houma, La. Posts: 11,734	Nice job I though about doing something similar for my Coolster 150. Thanks for sharing. __________________ 2024 Linhai 300 ATV 4x4 2023 Lifan Lycan 250 Chopper 2023 Venom Evader 2022 Lifan KPX250 2020 Kawasaki Vulcan S (Sold) 2004 Honda ST 1300 2016 Black Hawk 250 (sold) Keihin PE30 carb,125 main,38 slow.Pod filter,ported & decked head 10:1 CR,Direct Ignition Coil,15/40Sprockets,NGK DPR8EIX-9,De-Cat,Dual Oil Cooler,Digital Cluster 2016 Cazador180 XL 2014 Coolster150 JerryHawk250.com My YouTube Channel
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03-07-2017, 12:53 PM	#6
2LZ Join Date: Mar 2010 Location: Volcano, Ca Posts: 7,112	Nice work! The welding thing has always had me buffaloed. I can stick two pieces of metal together in a very ugly fashion, but I envy this kind of stuff. __________________ "Light a fire for a man, and you heat him for a day. Light a man on fire, and you heat him for the rest of his life." 2007 Suzuki DRZ400S (SM convert) 2009 Q Link XP 200 1967 BSA B25 250cc Starfire 2022 Royal Enfield Interceptor 650 2023 Royal Enfield Scram 411 1948 Royal Enfield Model G 350
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03-05-2017, 08:50 PM	#2
Darth Racer Join Date: Apr 2016 Location: MD Posts: 558	Nice job on the new pipes and welds.. Finish product looks stock!!
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03-07-2017, 06:33 PM	#7
BlackBike Join Date: Feb 2016 Location: George West, Texas Posts: 4,097	Great job, can a motorcycle engine crash guard be fashioned out of this conduct material. Practical? Would think it would be good for its light-weight properties. __________________ ***************************************** 2015 Bashan"Blaze" BS250GY-31 (DB-07K-250) GONE 2017 Suzuki V Strom 650 XT "We are all born ignorant, but one must work hard to remain stupid." ~Benjamin Franklin~
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03-07-2017, 07:13 PM	#8
david3921 Join Date: Feb 2009 Location: Michigan Posts: 1,043	Thanks guys. The little one is super happy he can ride with his papa. I wouldn't hesitate on using the conduit for guarding. The 3/4" stuff almost matches the tubing that most use for racks. You can get it with thicker walls also. __________________ 2012 Kawasaki Versys 1984 Honda Magna V65 2016 Rhino 250 2016 Tao Tao 125D
	1

03-16-2017, 02:01 PM	#9
FLASHLIGHTBOY Join Date: May 2009 Location: SASKATOON Posts: 1,161	seat the seat and rack looks great.... but I no one sits there as it is unsafe.( hate to sound like a doubter) but those racks are not made for much weight... and it could cause the atv to tip over... it might be good for a light kid.. or to sit back when you are resting on the trail... .. It is just a thing to think about.. good ob on it as I say __________________ DEALER FOR ZSTAR & GIO PRODUCTS, TAOTAO ABIBABA ATV ETC
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03-31-2017, 10:54 PM	#11
Slaphappy Join Date: Mar 2017 Location: Rochester NY Posts: 30	Man that looks good. Is there a way to strap the little guy in? Seems like a good bump might catapult him over the neighbors fence.
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