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[Wheaters]

Very nice, great job done!

(You could use a deburring tool to run around those ragged edges, not that they are seen with the panniers fitted).

[stinkwheel]

Michael Waller was just making flattened ends for tubular mudguard stays in his latest video. He made a neat little die for it and even placed small pieces of steel plate in the flattened part to make it perfectly flat and strong.
https://youtu.be/oEhpmJ3rrKg

Here's a short video of me cold-setting steel tube for a rear mudguard stay after packing it with sand.
https://youtu.be/95JAMQAzDE8

1mm wall tube seems perfectly adequate for luggage racks. I must have had 30-40kg of kit on this one last weekend.

[swiftjess]

Thank you everyone.

[LanesExplorer]

Thanks Wheaters.
I've been astonished to see that so many have watched the YouTube video and looked at these photos!
LE.