I couldn't see clearly.  Did you cut past the tab material and into the the 
bottom part of the hollow tube that forms the actual rack?!  If so and if 
it were me,  I'd graft ("sister") an additional piece of tubing (or bar or 
rod or scrap of aluminum nitto strut) next to it using jb weld or 
something, and then wrap the whole front section in twine for cosmetics.  
It may be fine as is but, if you did cut the bottom of the tube, it has 
zero remaining strength in bending resistance. 

If you left part of the tab on it and are just worried about sharp edges, 
I'd still think wrapping it in twine is a good option.

On Wednesday, July 31, 2024 at 11:52:42 PM UTC-6 [email protected] wrote:

> Ciao folks .. picked up a used Mark rack (appears to be a previous 
> iteration with the front tab for lighting). Spoke to someone at riv and 
> they suggested grinding it off as it comes too close to the tire (I run a 
> 2.1) and newer design of the rack has that tab omitted. A friend was 
> grinding it off with a circle grinder and what began as a clean cut became 
> a bit chunky upon completion (see video). How safe or unsafe is this rack 
> now? I’m running a basket and using it for sleeping bag and tent. I have 
> the rack strapped to my handle bars as well. Most of the weight is on the 
> back of the rack and this front bar does not appear to be much in terms of 
> load supporting anyway. Figured this was a good place to ask. Not ideal but 
> have a trip planned for Friday and in a bind! Vid attached.
>
>

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