I decided to start with the rear rack since it is somewhat simpler than the front rack. I'm starting with the horizontal elements of the rack.
I use a Ridgid manual tubing bender for stainless steel to make bends for racks like these. It mounts in a vise and has long levers for making the bends. I made the bends and trimmed the ends to the right dimension to fit around wheel/tire/fender. I then cleaned up the ends, and gave a quick grind to the threads of the eye bolts to allow them to fit snugly into the ends of the tubing. Fluxed and then torched.
Did a bit of clean up but will wait 'til the end to do final finishing.
