operation aluminium panniers

[bazza]

After a long time looking and thinking about having a go at makeing some panniers iv finnaly got round to it

As thay say when the boss is away the boys will play.
I got hold of some 3mm aluminium sheet and 3mm 2 1/2 cm x 2 1/2cm aluminium angle and sused out how to work the sheet metal cutter, so far so good,
Then started on the angle, now im no enginering god and it showed when i tryed to cut it to length and at a 45% angle but i got there in the end.

So far i have 2 box's held together with 4mm bolts.



Q, iv herd of people using steel rivets but wont they rust easy? and is there much in the strength?

I understand they could be stronger but if they do rust quite easy i might use alloy one's and get them spot welded on the inside just to strengthen them if thats doable.

I would just use the 4mm nut's but they look like they could catch on the in side even theo im going to line the inside with a canoe bag to help water proof and could hurt if i was to catch myself or someone.



So far its only taken me about 5hrs which i think is good for a first time experiment (i think thats what id call it)

Any advice would be much appretiated

[bazza]

anybody

[alpslapper]

Sorry I cant comment on anything rivit wise as Ive got no idea so no help to you at all - but they look well good to me and Im well impressed

Wish I could do stuff like that.

Nice one.

[Chunk]

anybody

Morning Bazza

I'll pass a couple of ideas your way a little later today.
I'm at work and the boss is hanging around..

[mick]

use stainless steel rivets they wont rust a lot stronger than ali .Forget about spotwelding the inside you need a special machine to spotweld ali.After you rivet panniers up, tap the inside of the rivets down make surethe rivet head is on something solid it works makes inside of box a lot smoother if you need anymore help pm me

[Chunk]

After a long time looking and thinking about having a go at makeing some panniers iv finnaly got round to it

As thay say when the boss is away the boys will play.
I got hold of some 3mm aluminium sheet and 3mm 2 1/2 cm x 2 1/2cm aluminium angle and sused out how to work the sheet metal cutter, so far so good,
Then started on the angle, now im no enginering god and it showed when i tryed to cut it to length and at a 45% angle but i got there in the end.

So far i have 2 box's held together with 4mm bolts.



Q, iv herd of people using steel rivets but wont they rust easy? and is there much in the strength?

I understand they could be stronger but if they do rust quite easy i might use alloy one's and get them spot welded on the inside just to strengthen them if thats doable.

I would just use the 4mm nut's but they look like they could catch on the in side even theo im going to line the inside with a canoe bag to help water proof and could hurt if i was to catch myself or someone.



So far its only taken me about 5hrs which i think is good for a first time experiment (i think thats what id call it)

Any advice would be much appretiated

Looking at the photos you've done a dam fine job so far.
People have used steel rivets on ally but you need to use solid countersunk ones from the outside in and round snap them to avoid catching inner bags.

Corrsoion shouldn't be a problem if you intend to powder coat them.

Spotwelding the angle to the sheet would cause a problem as the angle is a different spec to the sheet, Too much to go into on a post.

Have you had any thoughts on the lids and sealing them?

I want to get round to making some panniers and try to make them a damm site cheaper than Touratech.

Keep the post going with some more photos at the next stage..nice work so far.

[AIRWOLF]

Lookin good bazza.
I'm with mick on the stainless pop rivets if you want the extra strength, I usually get them from a chandlers,( they are used on mast fittings etc ).
There will also be different grades of alloy rivets available.
Or you could use 4mm bolts at the corners and ally rivets in-between.
All depends what's freely available.
Just got some 2mm ally sheet myself to make some boxes, I will be using 4mm ally pop rivets on mine, and covering rivets inside with strip of 'carrymat' or neoprene.

[Chad]

yup as said stainless rivets are fine but the two different metals together could cause corrosion problems ( osmosis) your better sticking with ali rivets then powder coating the whole shabang


looking good so far mate well done

[Snaphappy]

Before you rivet you might want to think about sealing the whole unit, I recommend Adheseal from Innotec, it will stick and stay flexible, silicone you cant paint over, and acrylic seals will dry eventually
hope this is of some help, for the top seals try edging rubber the reinforced stuf and make the lid to snug.

When your finished sell them to me for peanuts and make a new set, they look great

[bazza]

Thanks for all the info guy's, greate help as usual.
Job now on hold as iv been sent down south on a course for 2 weeks to learn how to drive tanks (what a bugger).

I am going to seal them but i cant remember what i have bought to do it, and i think i will go with the aluminium rivets.

Thanks again.