A few changes and improvements:
A timely buy at the local metals yard yielded a bit heavier aluminum stock.
I've switched from stainless steel pop rivets to solid aluminum aircraft rivets. The rivets are very secure and leakproof.
Finally, I located some "Harsh Environment" hinge material, and by bedding the hinge at install, we've got a pretty leak resistant/tight hinge now.
Some of you have added gasket material around the door. That, together with the solid rivets and sealed hinge makes for a fairly weathertight box.
This box fits the R1200GS/A with OEM panniers.
I'll have 6 boxes ready to go in about a week. Price unchanged...$120 for the box, $4 for paypal, $15 for shipping in USA.
If you PM, give me an email address and I'll get back to you that way.