Add to that the inevitable metal fatigue from prolonged use, and it might be prudent to buy a new rack. Blackburns EX-1 is an excellent choice, very beefy and built for touring. It has a 40-pound rating, and I expect that offers a pretty wide margin of safety. Retail is $45, but Nashbar (www.nashbar.com) currently has them for $35.
I also like Jandds Expedition Rack ($65; www.jandd.com). In fact, thats what I have on my Bob Jackson Special Tourist. Its a really rugged rack, rated to 50 pounds, and can easily handle as much stuff as you can pile on top of it.
Dunno what youre after for panniers. Jandd makes excellent ones$140 for a pair of Mountain Panniers, the cast-iron skillet of Jandds pannier line. Very rugged, with plenty of room for multi-day trips. But the Gold Standard for pack bags has to be the Ortlieb (www.ortliebusa.com) line of rugged, waterproof bags. The Bike Packer Plus is the flagship Ortlieb rear bag$200 for a pair. Excellent bags.
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