First up are a pair home made racks from Paul Woloshansky. Necessity being the mother of invention and fed up with broken racks, he decided to design his own (no welding required). You can see/read about what he came up with here. While he was at it, he decided to knock together some mudguards and panniers, all of which look pretty impressive/robust.
Ken Kifer also shares his design for homemade panniers here>>
B1ke 
November 8th, 2011 at 5:04 am
I’ve made several more lighter versions of my racks using 3/4″ rather than 1″ bar stock (25% lighter and commonly available in 1-metre pieces from Home Depot in North America-about $13CAD), as well as one-off front lowrider racks for assorted tourists (one with detachable folding Wald baskets).