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Old 06-06-2007, 12:40 PM   #1
ag_streak OP
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PennyTech - Has anyone made their own panniers?

Mermites - ammo cans - Pelican cases, lots of people have started with those, and modded & bolted 'em up to a rack. But has anybody MADE their own cans?

Sheet aluminum? Welded or riveted? Shop-made or done 'em yourself?

Pictures? Links? Instructions? Warnings?

Who's got the most ultimately-unique, custom, home-made, one-off panniers on this board?

ag_streak screwed with this post 06-06-2007 at 02:56 PM
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Old 06-06-2007, 12:52 PM   #2
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seen them here, but can't find them in a search now....
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Old 06-06-2007, 01:10 PM   #3
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I've seen 'em also, but for the life of me couldn't tell you where. It would seem that negligible sheet metal skills and a bucket o'rivets could yield some workable boxes. Better still, build some mockups in styrofoam, fiberglass/kevlar a shell. That's one more medium I've always wanted to play with but haven't had time..
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Old 06-06-2007, 02:16 PM   #4
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Panniers

I made my own. Like any project I found some ways to make the next set better. I have a press break and a TIG welder. They took a while to make. Longer than I'd like to admit to. I'm much happier with the bag mounts than the bags themselves. I have a picture of the bike floating around somewhere. Do a search on Twin headlight Ernie's KLR. Happy fabricating.
2HE
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Old 06-06-2007, 03:14 PM   #5
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Ah yes! I see those are built with the extruded edges and stamped or cast corners, the kind that come on many commercial equipment cases.

http://www.advrider.com/forums/showt...hlight=2he%27s

They're usually made of thin plywood sides, laminated to metal for appearance, then slid into the slots on the extruded metal edges.

Did you replace the sides, bottom, and top with thicker aluminum? Did you start with cases already built with the extrusions cut to that size? or did you find a source for the extrusions by the foot and create a custom size?




Quote:
Originally Posted by Twin headlight Ernie
I made my own. Like any project I found some ways to make the next set better. I have a press break and a TIG welder. They took a while to make. Longer than I'd like to admit to. I'm much happier with the bag mounts than the bags themselves. I have a picture of the bike floating around somewhere. Do a search on Twin headlight Ernie's KLR. Happy fabricating.
2HE
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Old 06-06-2007, 04:11 PM   #6
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I made a set a couple of years ago. Still got'em, still goin' strong

http://www.advrider.com/forums/showt...hlight=pelican
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Old 06-06-2007, 06:06 PM   #7
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Mr. Clang, those are very nice Pelicans, but not at all what I was looking for when posting this posting...


Quote:
Originally Posted by clang
I made a set a couple of years ago. Still got'em, still goin' strong

http://www.advrider.com/forums/showt...hlight=pelican
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Old 06-06-2007, 06:30 PM   #8
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Quote:
Originally Posted by ag_streak
Mr. Clang, those are very nice Pelicans, but not at all what I was looking for when posting this posting...
! My bad, missread the post
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Old 06-07-2007, 12:22 PM   #9
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This is what I'm thinking...

I have a welding shop nearby that specializes in custom aluminum fuel tanks for boats.

I'll give 'em my dimensions (about 10"w x 18"l x 14"h) and some drawings, and maybe a cardboard mockup, and tell them to build this out of .080" aluminum sheet...

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Old 06-07-2007, 12:23 PM   #10
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... then cut them like this...

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Old 06-07-2007, 12:23 PM   #11
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... so they open like this ...

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Old 06-07-2007, 12:24 PM   #12
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... and then add a lip like this ...

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What do you think?
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Old 06-07-2007, 01:13 PM   #13
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Do it.

I'd be very interested in the cost, and the shop probably will have suggestions for any bracing you may or may not need.

Keep us updated.
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Old 06-07-2007, 02:02 PM   #14
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Oh how I do love a good project
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Old 06-07-2007, 05:38 PM   #15
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panniers

imho,
the lip that you have devised would not be sufficient to create a seal. During rain/inclement condition water would track through the gap via cappilary atraction. You need some type of rubber seal and a catch that forces the lid to the seal.
cheers
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