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Old 11-08-2006, 10:13 AM   #31
the_gr8t_waldo
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i was at a local motorcycle dealer about two weeks ago, and out in the used bike herd was a klr650 with a pair mounted! i've always been interested in them as hard pantires. i have to say they looked great! imho, they look much more adventuresome that the zega boxes i now have. now i'm toying with the idea of buying a pair and modifying them, with an eye to selling my current ones- guys please don't contact me about buying them..thanx. as for the small internal canisters, camping stove and some food or maybe have them caped off and use them for extra fuel canisters( maybe straped on the rear?)
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Old 01-12-2008, 11:01 PM   #32
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I have seen those boxes around at disposal stores too, never thought of turning them into panniers. I will have to see if I can get my hands on some.

I hated the sight of the things as it always indicated that we would get crappy 1/2 cold mess food while out bush .

In the Australian Army, they are generally known at 'Hot Boxes'.

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Old 02-22-2008, 03:11 PM   #33
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I just sent for a rough pair of these. If they're aluminum, as they appear to be, I'm going to sandblast and clearcoat them. I'll post with updates when I get them and start the gutting process. In the meantime, can someone tell me where I can get the mounting hardware that makes these secure yet removable? I need both the part that goes on the box, and the part that goes to the rack since I'm going to be fabricating my own rack. I'll document the whole process for your viewing pleasure.
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Old 03-15-2008, 10:21 PM   #34
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Pilot, thank you for posting this. My pannier hunt just got much cheaper and more interesting.
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Old 03-16-2008, 08:50 AM   #35
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Glad we have another participant in the home fabricated pannier thread. I thought this thread had gone dormant. Good news, I got mine in. I got what I paid for at $50+ shipping, they're pretty dented but it's good that you can easily exchange lids. I'm going to gut mine this weekend.
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Old 03-16-2008, 09:18 AM   #36
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Then I need to fabricate a rack using some ideas from the post your pics of xr650 L racks and bags thread.

I like forrestbault's rck on page 3. Check out the thread^.
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Old 03-16-2008, 11:52 AM   #37
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Here are some more ideas for penny-tech panniers.



Note the innovative soft-bag hanging off the handlebars!
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Old 03-16-2008, 12:19 PM   #38
the_gr8t_waldo
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as far as securing then to a rack, i liked my klr mountings. the rack had threaded holes on the rack. all i did was put 4 bolts from the inside of the box into the threaded holes each side. i placed a large square washers on the inside to spread out the load. useing one of the wrenches in my tool kit, it was tightened down. no one could get to the bolt heads with out opening the boxes. and the protruding bolt heads were not a problem, like you'd think they would be.
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Old 03-16-2008, 11:09 PM   #39
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I gutted mine today. I used about 4 fiberglass reinforced Dremel cutoff wheels and one and a half 4-1/2" angle grinder wheels. I cut the inner lining about an inch and a half below the inner gasket lip to preserve the strength of the gasket/lip watertightness when clamping the cans shut. Then, after the perimeter cut, I cut the inner can into 4 pieces and they pried out easily. then, scraping the foam out took for ever and was a huge pain. You only do this once, I kept thinking. The foam leaves a residue on the inside that must be scraped out, and can't quite all be scraped clean, as you can see in the photos. I'm going to see if the last of the residue can be sandblasted off when I go to get the outsides of my cans blasted. I'm going to then clearcoat them as I said earlier. The first guy I gave them to for blasting only got one side of one of the cans done, and said it took 2-1/2 hours to get that far, so he stopped before billing me at that rate. He says they're sprayed with some kind of chromate etching primer that is super hard to get off. So now it's off to the othe guy he recommended with an actual SAND blaster as opposed to the fine glass bead he has in his blasting cabinet. I might go back to the first guy just for a finish blast before the clear coat.
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1983 Toyota pickup: total overhaul, preservation-restoration in constant progress...
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I do heavy-duty textile repair, upholstery, and design/manufacture bags.

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Old 06-05-2008, 03:59 AM   #40
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Quote:
Originally Posted by oio
Here are some more ideas for penny-tech panniers.



Note the innovative soft-bag hanging off the handlebars!

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Old 06-07-2008, 07:00 PM   #41
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Puke

oh BTW I was a food Svc specialist in the US Army and mermites should have a few holes on the outside to prevent the insulation from swelling and ruining the can...
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Old 06-07-2008, 11:22 PM   #42
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Perhaps you guys should look into ultralight backpacking, or read and heed the words of Ray Jardine. Google for such. It seems that some in the backpacking crowd have whittled their gear down to a total of 5 or 10 lbs.

Adaptation of such weight savings and compact equipment would obviate use of all of this clunky stuff on a motorcycle.

More aerodynamic packaging would not hurt, either. Some of the pics posted seem to be in a contest for who can make the heaviest, draggiest motorcycle on the planet. Just sayin.'

All that extra weight and bulk cannot be helping your handling or fuel economy, either.
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Old 06-08-2008, 12:30 AM   #43
Zombie_Stomp
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Quote:
Originally Posted by RSL
Adaptation of such weight savings and compact equipment would obviate use of all of this clunky stuff on a motorcycle.

More aerodynamic packaging would not hurt, either. Some of the pics posted seem to be in a contest for who can make the heaviest, draggiest motorcycle on the planet. Just sayin.'

All that extra weight and bulk cannot be helping your handling or fuel economy, either.
Which is the clunky stuff? I think the Mermites, when fully gutted including the insulated lid, are pretty damn light. Have you ever held one? The main point is CHEAP. I CANNOT afford a $700 set of hard panniers. Or $200 for that matter. That said, I'll look into your suggestion of looking up that guy's writings, as I can always look forward to new info.
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1983 Toyota pickup: total overhaul, preservation-restoration in constant progress...
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STOLEN: RED XL600 in Portland

I do heavy-duty textile repair, upholstery, and design/manufacture bags.
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Old 06-08-2008, 03:19 AM   #44
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Quote:
Originally Posted by RSL
Perhaps you guys should look into ultralight backpacking, or read and heed the words of Ray Jardine. Google for such. It seems that some in the backpacking crowd have whittled their gear down to a total of 5 or 10 lbs.

Adaptation of such weight savings and compact equipment would obviate use of all of this clunky stuff on a motorcycle.
So show us your camping setup on the MC and off.

Ray probably doesn't spend all day with 70mph winds. I can easily hit 10 Lbs on a day trip if the weather starts cold, turns hot, and may rain at any time. I'm including the tools in that weight. For camping, my gear is fairly bulky but not heavy. That said, my next trip will see me carrying 30 or 35 Lbs for camping plus a city visit.

EDIT: Oh, and I'm taking a quart of Maine maple syrup to my Dad and bringing home a few yards of that really heavy coated nylon that's been in his basement. Sounds like about 40 Lbs.
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Old 06-08-2008, 08:42 AM   #45
Zombie_Stomp
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These stick out too far, but worth posting. He's got a nice shine on them. Mine are in a rough finish, having been recently blasted with real sand. I need to bead blast and then polish or clearcoat, most likely trhe latter. Then I gotta build a yoke to throw over my rack to put them on that is as close in board, forward, and low as possible. Pics to follow.
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