Penny Tech Panniers

pilot · 05-15-2003, 11:09 AM

Tired of high prices for panniers? These do the trick at around $100 a pair. These are Merimite Food Containers courtesy of good old Uncle Sam.

pilot · 05-15-2003, 11:11 AM

This is what you get. They come with these annoying inner cans. If anyone knows what to do with these, let me know.

pilot · 05-15-2003, 11:16 AM

Give these away if you can.

pilot · 05-15-2003, 11:19 AM

Remove the gasket and cut here all the way around the liner with a sabre saw.

RealpolitiKLR · 04-08-2005, 10:25 PM

Quote:

Originally Posted by pilot

Remove the gasket and cut here all the way around the liner with a sabre saw.

Will the gasket still seat itself well without that inner lip to snug up against?
-RealpolitiKLR

Surly · 04-09-2005, 10:35 AM

Quote:

Originally Posted by RealpolitiKLR

Will the gasket still seat itself well without that inner lip to snug up against?
-RealpolitiKLR

I think they will as its downward and not inward pressure
I chose to leave a portion of the alum liner on my bags however

RLK · 07-10-2005, 07:13 PM

I grabbed one mermite can to convert to a top case. The can I got looks like it has already had a hard life. I have found 4 holes in the outer case but I didn't find them untill I ripped the inner can out. The insulation had already fallen off the inside and was all laying in the bottom.

I'd not reccomend buying a surplus Mermite online or mail-order. Before you buy, inspect it carefully.

SmugMug is taking its sweet time with my pictures but i'll post them and explain what I found in my can ASAP.

RLK · 07-10-2005, 08:13 PM

I started by taking an angle grinder to the inner liner, about an inch below the lip, thinking that leaving the top inch of metal would help hold the gasket in place. After prying out the inner part, I found all of the insulationlaying loose in the bottom.

I don't think its supposed to look like this:

Removal of the insulation was a snap. It all just dumped out. What was left came out with a dish scrub/sponge and plain water. After It was clean I found holes in the bottom.

In the bottom, the insulation has 3 "bars" (for lack of a better term) of more dense insulation. They are located where the metal appears more greyish in this picture.

In the center, that's a blade of grass sticking up from below. Two more smaller holes are visible, kinda left-center. Not visible is a small hole in the seam between the end wall and the floor and another pinhole on one end wall, below the handle.

While I was working on it, the top inch of the inner liner that I wanted to leave just kind of fell out.

As a temp. fix I just duct taped over the holes and all around the floor seam. Hopefully that will keep it somewhat water resistant for a while.
I didn't encounter any rain over the first weekend out with this thing but I hold little hope for its long term road-worthyness. Hopefully I can get my $12.50 out of it.

Here's how I set it up. Go ahead and laugh, I know its rediculous.
Its double ratchet-strapped to the subframe, not just bungeed. The bungees are for redundancy

All I can say is, INSPECT YOUR CANS CAREFULLY BEFORE BUYING.

pilot · 05-15-2003, 11:22 AM

Next cut the liner in half lengthwise. I used an angle grinder. This is the worst part of the whole process. Then pry, cuss, pry, and pull these out of the boxes.

pilot · 05-15-2003, 11:28 AM

You then have to remove the insulation from the inside of the can. I used a putty knife to scrape all the foam out starting about an inch down from the fiber gasket surface. I left the top inch in to support the gasket surface. I then painted the interior with truck bed liner in a can. Use plenty on the foam at the top.

Next is the latch and mount. I used eyebolts from Airparts for the lock hasp. Drill and cut out the tab to allow the eyebolt to pass through. The Happy Trails mount bolts on the back. Two more holes at the top for the hold on bolts and your through.

pilot · 05-15-2003, 11:31 AM

Here is the completed latch.

pilot · 05-15-2003, 11:32 AM

This is the Happy Trails mount.

pilot · 05-15-2003, 11:36 AM

Here is the rear view of the bags on the bike. This is the setup I used through Mexico and Guatemala this winter. Lots of room, water tite, secure, and quite ugly to match the KLR.
You don't have to worry about trashing a $1000 set of boxes if you fall over. I didn't crash test them yet, so I don't know how well they hold up to abuse, but for the money, who cares?

Chopperman · 05-15-2003, 11:38 AM

Quote:

Said pilot:
Give these away if you can.

You can make a pine cone stove out of those. Or a parts container. Or stuff your tool roll in there to keep the greasy bits off your shaving kit. thousands of uses

Ricardo Kuhn · 05-15-2003, 11:42 AM

Love the care you took to explain the whole thing.

I thank you in the name of everybody,that belive in autonomy, I love the felling of creation....

Great JOB

05-15-2003, 11:09 AM	#1
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	Penny Tech Panniers Tired of high prices for panniers? These do the trick at around $100 a pair. These are Merimite Food Containers courtesy of good old Uncle Sam. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:16 AM

05-15-2003, 11:11 AM	#2
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	more This is what you get. They come with these annoying inner cans. If anyone knows what to do with these, let me know. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:17 AM

05-15-2003, 11:16 AM	#3
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	cans Give these away if you can. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:18 AM

05-15-2003, 11:19 AM	#4
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	cut here Remove the gasket and cut here all the way around the liner with a sabre saw. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:18 AM

07-10-2005, 07:13 PM	#7
RLK 4,949 Joined: Nov 2004 Location: CSprings Oddometer: 6,005	More on Mermite I grabbed one mermite can to convert to a top case. The can I got looks like it has already had a hard life. I have found 4 holes in the outer case but I didn't find them untill I ripped the inner can out. The insulation had already fallen off the inside and was all laying in the bottom. I'd not reccomend buying a surplus Mermite online or mail-order. Before you buy, inspect it carefully. SmugMug is taking its sweet time with my pictures but i'll post them and explain what I found in my can ASAP. __________________ It takes less time to do things the hard way than to be too nervous to even start at all. -Juanito on the Yahoo!

07-10-2005, 08:13 PM	#8
RLK 4,949 Joined: Nov 2004 Location: CSprings Oddometer: 6,005	I started by taking an angle grinder to the inner liner, about an inch below the lip, thinking that leaving the top inch of metal would help hold the gasket in place. After prying out the inner part, I found all of the insulationlaying loose in the bottom. I don't think its supposed to look like this: Removal of the insulation was a snap. It all just dumped out. What was left came out with a dish scrub/sponge and plain water. After It was clean I found holes in the bottom. In the bottom, the insulation has 3 "bars" (for lack of a better term) of more dense insulation. They are located where the metal appears more greyish in this picture. In the center, that's a blade of grass sticking up from below. Two more smaller holes are visible, kinda left-center. Not visible is a small hole in the seam between the end wall and the floor and another pinhole on one end wall, below the handle. While I was working on it, the top inch of the inner liner that I wanted to leave just kind of fell out. As a temp. fix I just duct taped over the holes and all around the floor seam. Hopefully that will keep it somewhat water resistant for a while. I didn't encounter any rain over the first weekend out with this thing but I hold little hope for its long term road-worthyness. Hopefully I can get my $12.50 out of it. Here's how I set it up. Go ahead and laugh, I know its rediculous. Its double ratchet-strapped to the subframe, not just bungeed. The bungees are for redundancy All I can say is, INSPECT YOUR CANS CAREFULLY BEFORE BUYING. __________________ It takes less time to do things the hard way than to be too nervous to even start at all. -Juanito on the Yahoo! RLK screwed with this post 07-10-2005 at 08:19 PM

05-15-2003, 11:22 AM	#9
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	remove liners Next cut the liner in half lengthwise. I used an angle grinder. This is the worst part of the whole process. Then pry, cuss, pry, and pull these out of the boxes. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:19 AM

05-15-2003, 11:28 AM	#10
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	remove insulation You then have to remove the insulation from the inside of the can. I used a putty knife to scrape all the foam out starting about an inch down from the fiber gasket surface. I left the top inch in to support the gasket surface. I then painted the interior with truck bed liner in a can. Use plenty on the foam at the top. Next is the latch and mount. I used eyebolts from Airparts for the lock hasp. Drill and cut out the tab to allow the eyebolt to pass through. The Happy Trails mount bolts on the back. Two more holes at the top for the hold on bolts and your through. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:20 AM

05-15-2003, 11:31 AM	#11
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	completed latch Here is the completed latch. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:21 AM

05-15-2003, 11:32 AM	#12
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	mount This is the Happy Trails mount. Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:21 AM

05-15-2003, 11:36 AM	#13
pilot ^OP Slacker Joined: Dec 2002 Location: Kansas City Oddometer: 29,536	rear view Here is the rear view of the bags on the bike. This is the setup I used through Mexico and Guatemala this winter. Lots of room, water tite, secure, and quite ugly to match the KLR. You don't have to worry about trashing a $1000 set of boxes if you fall over. I didn't crash test them yet, so I don't know how well they hold up to abuse, but for the money, who cares? Attached Images __________________ The finishers medal is satisfyingly heavy... Neduro on Dakar The other 10% are sociopaths , serial killers and KLR riders. You wont get much sympathy from them. -Furious D pilot screwed with this post 02-05-2010 at 07:23 AM

05-15-2003, 11:42 AM	#15
Ricardo Kuhn a.k.a. Mr Rico Suave Joined: Sep 2001 Location: Salt lake city, Utah Oddometer: 11,606	Exelent Work,,actually those bags are Perfect size Love the care you took to explain the whole thing. I thank you in the name of everybody,that belive in autonomy, I love the felling of creation.... Great JOB __________________ I'm really Sorry but I'm "Out" of Rickybars, Actually I have a bunch of bars and a Ton of end pieces but Not that many clamps to offer them as a product anymore.

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