Luggage Rack Installation
Q: I could get the bolts that came with the rack (which was purchased used) part way in, but with the rack being narrow, he could only get so far, and thus the toolbox would not fit in the space that remained. Suggestions?
First make sure all the other bolts are very loose...then tighten the bolts going to the seat rail slowly..going from one side to the other.. to keep them even. Eventualy they will bend out the rack tubes into position. Then tighten the other bolts down (on the fender rail) Mine was like this also..but as long as you can get all the bolts started you will be fine.( no you can't use the stock bolts...you need to use the ones that came with the rack.) I think I ended up replacing mine with allen heads when I did the backrest.
Yes, you need slightly longer bolts than the stock ones. Also, the heads should be rounded/low profile in order to get the tool box back in. Make sure you use appropriate lock washers (I'm using star locks rather than split locks). Let me know how it goes.