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-   -   Handmade Alu Panniers (The Greek Way) (http://www.advrider.com/forums/showthread.php?t=813136)

B_B 07-30-2012 03:33 PM

Handmade Alu Panniers (The Greek Way)
 
In this thread i'm gonna try to present you a short story about three friends and a plan...
The story began to be written on a rainy afternoon in November of 2011, in a small village in central Greece, when I visited my friend Fotis in his lab to discuss an idea that has long turned my head. To fabricate aluminum panniers for my motorcycle, a Honda African Twin 750 cc.
The hot coffee had been served and my friend was ready to hear my idea. An hour later and after I explained what I wanted to make his response was that we will try to implement the Aluminium Panniers idea.
The next day our friend Panagiotis, who is a designer, was already in front of his computer monitor by taking the design of the panniers.


Phase 1 Design and Development by Panagiotis
http://2.bp.blogspot.com/-VBItP-oPxE...0/DSC02234.JPG

Working on AutoCad and after some hours the results was fairly well.
http://2.bp.blogspot.com/-_N9kNMsU4o...0/DSC02243.JPG

http://2.bp.blogspot.com/-vnndigJUSs...0/DSC02245.JPG

A 35 ltr pannier
http://3.bp.blogspot.com/-Jez2FwVzSc...0/DSC02237.JPG

http://4.bp.blogspot.com/-HoTgpHeNoj...0/DSC02241.JPG

http://3.bp.blogspot.com/-JZ2E0tGhD8...0/DSC02242.JPG

http://4.bp.blogspot.com/-vArVz0rma-...0/DSC02248.JPG

Phase 2 Design Patterns by Fotis
http://4.bp.blogspot.com/-M7Sqndfw3R...0/DSC02254.JPG

and cutting the aluminium parts
http://4.bp.blogspot.com/-u0lixwi2r0...E%25B10130.jpg

http://2.bp.blogspot.com/-rO4GdxMK6q...E%25B10131.jpg

http://3.bp.blogspot.com/-TmMC24ri2P...E%25B10128.jpg

http://4.bp.blogspot.com/-u09nHAJlU7...E%25B10132.jpg

http://4.bp.blogspot.com/-xCL2AxxyX7...E%25B10134.jpg

http://4.bp.blogspot.com/-ZLz0vDrmOH...E%25B10129.jpg
Our first panniers is a fact !!!

Phase 3 Βonding
http://3.bp.blogspot.com/-NxJ1M_9bI1...x+712%2529.jpg

http://2.bp.blogspot.com/-L9QV6YBNK_...x+712%2529.jpg

http://3.bp.blogspot.com/-69DhfaSWsD...x+712%2529.jpg

http://3.bp.blogspot.com/-0ezM71sX95...x+712%2529.jpg

http://4.bp.blogspot.com/-bC3CSaQfQj...x+712%2529.jpg

http://2.bp.blogspot.com/-v4pWR3tloo...x+712%2529.jpg

http://1.bp.blogspot.com/--JrIsg3tGx...+1072%2529.jpg

And the result was this...
http://1.bp.blogspot.com/-AWGOlYk47X...x+675%2529.jpg

http://3.bp.blogspot.com/-9gH5C0e6Q5...x+712%2529.jpg

http://4.bp.blogspot.com/-JuYVC07w6G...x+682%2529.jpg

http://3.bp.blogspot.com/-0RILyCcuCj...x+670%2529.jpg

http://1.bp.blogspot.com/-_Gki93EG_P...x+568%2529.jpg

but....something was wrong and we had to find out what we must re-design and correct...

More in a while...
http://3.bp.blogspot.com/-1J2RjcrFlu...x+939%2529.jpg

Hotmamaandme 07-30-2012 06:53 PM

Keep up the good work I need some for my Honda Transalp

B_B 09-02-2012 12:10 PM

Thanks mate.

So, we had to re-desigh and find other materials to equip our alu panniers.
Things was not so easy 'cause we wanted top quality product without the prize to reach high.
And we started again the tests until we reached our goal :evil

Pictures below is from our final result. A 42 and 35 lit set of alu panniers for my Honda Africa Twin.
http://2.bp.blogspot.com/-qAU95-LuYc...9+x+712%29.jpg

http://4.bp.blogspot.com/-du1kFEvdFA...2+x+712%29.jpg

Side bars is handmade also
http://1.bp.blogspot.com/-2MPkinVb36...2+x+712%29.jpg

http://2.bp.blogspot.com/-OzFEqx-OFj...2+x+712%29.jpg

Mounting kit (no plastic used, only some elastic parts to prevent scratches to our boxes)
http://1.bp.blogspot.com/-zEzNAxAefU...2+x+712%29.jpg

http://3.bp.blogspot.com/-3wCFGrJt0v...2+x+712%29.jpg

http://3.bp.blogspot.com/-xYgyFCc6s2...+x+1072%29.jpg

http://2.bp.blogspot.com/-kZKKezH9T1...+1072%2529.jpg

http://3.bp.blogspot.com/-Qh6-yq0lK2...2+x+712%29.jpg

http://4.bp.blogspot.com/-f4Xt3jk7tk...+x+1072%29.jpg

And our first test

http://www.youtube.com/watch?feature...&v=jytYRZkH6ok

10 kgrs in each box
150 km/h max speed

B_B 09-02-2012 12:25 PM

The result was what we were expected but i didn't like the gap between the exhaust and the the alu panniers at the right side of my old lady, so we decided to make a new set of 2 42 lit boxes with the right alu panniers to "hug" the exhaust.
http://3.bp.blogspot.com/-4BUsQxGCk3...0/_DSC1702.JPG

http://1.bp.blogspot.com/-ja-nAMFHIB...0/_DSC1676.JPG

http://3.bp.blogspot.com/-n8VSRA2icS...0/_DSC1665.JPG

http://1.bp.blogspot.com/-g3PDOA8OXN...396+x+927).jpg

http://1.bp.blogspot.com/-j7lRtd7iF7...0/_DSC1651.JPG

B_B 09-02-2012 12:36 PM

And here are some details of our alu panniers

2 mm in aluminum box and lid.
Seal in a box and lid.
Soldering inside and outside of the box.
Open locks the whole set (4 locks) with a key.

Foot dragger 09-02-2012 12:42 PM

VERY NIIIICE! I love stuff made by guys just figuring it out and doing it,If you guys can build that you can build all kinds of trick things for bikes! I like it. Maybe get a seamstress and build form fitting bags that go in them as an option,Ive always like leaving the boxes on the bike and taking the bags inside.

B_B 09-02-2012 12:43 PM

Some friends saw our alu panniers and they asked to make for their bikes also a set and we said "why not?" :clap
Below are pics from our friends bikes

BMW 1200GS ADV (set of 42 lit alu panniers)
https://fbcdn-sphotos-f-a.akamaihd.n...28986136_n.jpg

On touratech side bars
https://fbcdn-sphotos-e-a.akamaihd.n...31599755_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.n...66570891_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.n...83398072_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...56922020_n.jpg

https://fbcdn-sphotos-e-a.akamaihd.n...78046635_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...33849613_n.jpg

B_B 09-02-2012 12:47 PM

Yamaha XT660Z Tenere (set 35 lit)
https://fbcdn-sphotos-a-a.akamaihd.n...59238420_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.n...85101291_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.n...43128396_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...15187970_n.jpg

B_B 09-02-2012 12:50 PM

BMW 800GS (set 35 lit)
https://fbcdn-sphotos-h-a.akamaihd.n...47729481_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...32385754_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.n...19651448_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.n...46844881_n.jpg

B_B 09-02-2012 12:53 PM

Quote:

Originally Posted by Foot dragger (Post 19503489)
VERY NIIIICE! I love stuff made by guys just figuring it out and doing it,If you guys can build that you can build all kinds of trick things for bikes! I like it. Maybe get a seamstress and build form fitting bags that go in them as an option,Ive always like leaving the boxes on the bike and taking the bags inside.

Thanks a lot mate !!!
We are already in the search for the fitting bags and for more other gadgets for the boxes :thumb

B_B 09-02-2012 12:57 PM

BMW 1200GS '07 (set 42 lit on Holan side bars, Total Black Edition)
https://fbcdn-sphotos-g-a.akamaihd.n...01245818_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.n...78246473_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...90251414_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.n...45763052_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.n...04275650_n.jpg

https://fbcdn-sphotos-f-a.akamaihd.n...06979098_n.jpg

B_B 09-02-2012 12:59 PM

BMW 1200GS (set of 42, 35 lit on Givi side bars)
https://fbcdn-sphotos-h-a.akamaihd.n...46298279_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...00533180_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.n...50704368_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.n...46038041_n.jpg

https://fbcdn-sphotos-c-a.akamaihd.n...29710078_n.jpg

B_B 09-02-2012 01:03 PM

Honda xl1000v Varadero (set of 38lit with alu stamps)
https://fbcdn-sphotos-h-a.akamaihd.n...82378209_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...03402625_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.n...82772622_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.n...06706756_n.jpg

B_B 09-02-2012 01:06 PM

BMW 650GS (set of 42lit in alu colour with black finishing)
https://fbcdn-sphotos-d-a.akamaihd.n...79368961_n.jpg

https://fbcdn-sphotos-h-a.akamaihd.n...98731567_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.n...23037425_n.jpg

https://fbcdn-sphotos-d-a.akamaihd.n...56575341_n.jpg

https://fbcdn-sphotos-g-a.akamaihd.n...15497418_n.jpg

https://fbcdn-sphotos-a-a.akamaihd.n...94586142_n.jpg

https://fbcdn-sphotos-b-a.akamaihd.n...03438960_n.jpg

B_B 09-02-2012 01:09 PM

For more info and pics you can visit our fb page and in a few days at our web page www.atlaspanniers.com

p.s Thanks a lot AdvRider for the hospitality of our work !!!!!!!


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