For the actual mounts, I switched to 1/8 x 1 steel stock. The one or two ounces of weight I might have saved with aluminum just didn't concern me when compared to the possibility of cracking or crushing of the mounts.
Here are some pics of the plate installed and then in use. I have to guess I had more than 50# on it for the entire trip. The load is mounted forward, very low when compared to using a topcase, and there is very little problem with handling changes. Basically the bike just gets a little more heavy.
Again, this kind of thing can be fabricated for any sort of bike. TW200 to GL1800.
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