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>>