Home made panniers...

[Xander]

Hi guys,
As my winter projects thread suggested I am going to be installing my custom panniers on to Anubis this winter. I made these boxes a few years back for my XTZ and will be changing them a bit to suit my new needs. So I had a friend ship em to me from Aus.

Last night i did dig out the original design plans, these were made of 1.5 ali sheet and folded where it was possible and welded where not..
This it the concept drawing...


Well i just got a call from Mrs.X who is home sick (), that my panniers are here!!! I thought they would take months but apparently 8 days is all it takes.. for two big boxes to be shipped from Aus and only cost me 80£!!! UP YOURS TOURATECH!!! and the alli sheet only cost me $30AUD!


Now I think some of the measurements were changed during construction so ignore the numbers...but that gives you an idea of the shape..

Of anyone who is interested this is the flat cut drawing...



I will take some pics tonight and will keep you informed of the modifications that will happen.. but i am like a kid at Chrissy.. I cant seem to concentrate on work now!!!

[Xander]

Well, even though no one seems to care about his post here is the pics of the new paniers..
The pipe side box will get scaloped out to fit the pipe, either as a high pipe or as normal not decided yet.

I may get them powder coated ALA Stormforce.

[Paul-S]

In Black maybe?

See, I care and they look nice

[Lord Vader]

Well, even though no one seems to care about his post here is the pics of the new paniers..
The pipe side box will get scaloped out to fit the pipe, either as a high pipe or as normal not decided yet.

I may get them powder coated ALA Stormforce.

I do a lot but
if i look at it too much i start crying cause i want a set but can not afford them at the mo

[Stormforce8]

Well, even though no one seems to care about his post here is the pics of the new paniers..
The pipe side box will get scaloped out to fit the pipe, either as a high pipe or as normal not decided yet.

I may get them powder coated ALA Stormforce.

Xander - have you considered the possibility of of strengthening the folded corners with something (possibly ally angle)

Are you adding any tie down points?

I can thoroughly recommend the LED tail/brake lights (PM or phone if you want details)

What locking system are you thinking of using?

What are you using on the lip of the cases to make them waterproof?

Also - for the 'matt' effect powdercoat make sure you specify 30% gloss

So many questions.................but it's only 'cos I care......

[Jenna]

look good and a nice design but sadly im still a peliconvert.

have to say i do think they look way better matt black, gloss black is a bit chav and well lets be honest bare ally is sooooo last year!.

[Krtek]

Home made panniers rule. Nothing fits your bike better.
How wide will the bike be with those on?

[Stormforce8]

have to say i do think they look way better matt black, gloss black is a bit chav and well lets be honest bare ally is sooooo last year!.

HELL YEAHHHH........









I know, I know..........but I just can't resist it............

[alpslapper]

Xander - looks good mate - agree with the matt black comments - just wish I could do stuff like that. Nice one.

[Xander]

Xander - have you considered the possibility of of strengthening the folded corners with something (possibly ally angle)

Are you adding any tie down points?

I can thoroughly recommend the LED tail/brake lights (PM or phone if you want details)

What locking system are you thinking of using?

What are you using on the lip of the cases to make them waterproof?

Also - for the 'matt' effect powdercoat make sure you specify 30% gloss

So many questions.................but it's only 'cos I care......

To answer the Questions.. I chose the folds angles to maxims strength (yes i actually calculated the angle tension to be at the maximum...I am a science geek piss off the lot of you.... remember a 45deg angle is much stronger then a 90.. ) so i don't think it needs any supports in there the bottom plate is 2mm ali and the rest is 1.5 (I would have made in them in less (like 1mm) re the tread where Jenna calculated the weights.. but hell i did not even know this forum existed 3 or 4 years back when i made these. I would have kept the bottom 2 mm though.. )

All cuts have been welded inside and out and well a few years back I sat my long wheel base nissan patrol ('84) on them while upgrading the shockers/springs... so I am convinced that they are tough enough.

Tie downs yup.. but only on top. and a carry handle as well.

Right now they are set up to fit a Teshe style rack (think square tube touratech style.. ) so that will all change.
I have also got hold of a Jesse rack for a Vstrom which will donated parts for the new rack. So a bit of cutting and welding is needed there... Chad oh Chad.. got a free weekend in December? (it is only mild steel.. and I have no welder here.. ). If i had a garage or a shed i may buy one.. but i dont... so a welder living in the bedroom is a great way to kill romance.. even asking is not worth it... (she has let me do a little silver soldering in the kitchen though)

I am thinking of using HB golbi latches.. The protex are great but once you go for keyed alike they are very exxy.. and I like the over the centre draw style better then the swing arm. In fact I will order them soonish.

The water proofing will be simple compression rubber gasket.. acentric 3 rib stuff. cheep cheerful and in my experience effective. (like activemoto's site).

As for the powder coating.. the colour is in debate.. I love the look of your (storm's) black.. but am worried that in major solar heat. they will get very hot. Mrs.X thinks we should match it to the top box.. (so i may get that shot at the same time).. but it may all be silver.. I dont know.. "maken them purty" comes way last in my humble opinion..Hard anod. is also a possibility... but I will be adding the 3m reflective tape to the rear no matter what...

The other mods.. Right now they are both a bit wide.. so I am going to cut 2.5 cm off the back of the non-can side and see what it needs for the can side it will be scalloped but not sure best way. standard pipe big top.. but angular scallop.. high pipe small opening but linear scalloping.. What would you the learned members on this forum want???..

my biggest issue is that i do not have any of the tool I need in this country and so will have to pay (yuck dont even like to say it) a sheet metal shop to make the mods for me... oh i feel dirty..

I would like to get these to be as close fitting as possible.. and this may take some major work...

As for the stop lights ...Storm... you sent me the details already (thanks). Something like this will happen.

activmoto- AS for the mounting I am very very convinced that quick release is worth it.. camping i take em off for use as tables seats/ wind braces.. and when touring, if we stay in a hotel for a couple of days i just carry them in as luggage.. and then the bike is light/ narrow again.. soooo sooo worth it..

I recon the TT/Teche style is the easiest mount to make .. but to be honest i dont like the looks.. the new speedy clip hepco is kinda neat..who has that on here?

But for my liking i think Jesse has it right (the standard not the new speed clip).. they are rear crash bars and racks in one. so this is my plan they dont make em for the AT but anything can be made to fit!