Build your own metal panniers on a budget !!

Build your own

Hi,
Here's some I "produced earlier" - made sides and a top box.
If it helps here is the breakdown of dimensions and cost for the the 2 side boxes. Mine were made to be just inside the size of my bars, when mounted on Givi frames.
I made these 2 side first and followed on with the top box.

For info the cost of the side boxes was as follows -
Sizes - Length 520 mm @ Height 350 mm and I made 2 widths of 180 mm and 200 mm to accommodate my exhaust box.

My 2 Givi inner carry bags fit inside each.

1- Aluminium cut to size and delivered - panels 2 mm and angles 1.6 mm = £112 - [ this price could be reduced by finding a local supplier and if you wanted to cut yourself]
2- 4 latches = £16.60
3- 8 steel corners covers for lids = £8.90 - Focus or Wickes
4- 4 Padlocks = £ 9.99
5- 4 Handles = £6.00
6- 8 Steel Ball covers for base corners [65 mm 3 legs] = £ 6.40 - ESR Components Ltd -http://www.theelectronicsshop.co.uk/Products/Hardware.htm [ corners ]
7- 8 Bolts for lids corners = £2
8- 200 pop rivets = £ 4.

Total £165

Plus silicone and tape etc.

Tools -

Sharp drill and centre tap, clamps, old surform [ found you could "plane" the Alu to adjust final size if required if required.] Pop riveter.

Here are some pics.

Cheers,

Mac
 

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They look good, I like the price, how are you mounting them ?
I wonder how the riveted look would be with the angles on the inside ? (Maybe just the outside corner verticals)
Stewart
 
Alu Boxes

I built mine the same way you would build an all glass aquarium -use duck tape to create the box shapes - apply the sealant and leave to cure. Then apply the angles. The final result was very strong.
I bolted mine directly to the existing Givi 4 bolt mounts - I put in some small steel plates [or big heavy duty washers ] on the inside of the boxes where the bolts came through to take the weight off the aluminium. It was a very quick job with one spanner to take them off.

I did not attempt to create mitres under the corners - stronger using square steps.

Some more pics attached.

Cheers,

Mac
 

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More pics

More pics of Alu Boxes - hope this helps
 

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Mac those boxes are minted ,:thumb2 where did you get the corner plates for the lids ?? do you have a link ?? i feel a pannier build off starting here :thumb2
 
anyone got any better ideas for quick disconnect panniers ?? i dont fancy the idea of having to empty them and then undo bolts if i can avoid it :thumb2:thumb2
 
excellent popeye , what pannier rails are those ?? and do you have part numbers / supplier details for the fasteners ?? thanks in advance ...kikry :thumb2
 
Big Al and Quick Nick built a good QD mounting system resembling the TT pucks from some plastic bar stock and nuts and bolts.
Stewart
 
My 10 cents...

There are special pop rivets used for roof sheet metal.
These have a "blind bottom" (shaped lik a cup instead of a pipe) and are also equippes with a small rubber seal, thus waterproof.
The rubber material in the seal is UV-resistant and made to withstand aging and weathering,

PJ
 
Just a quickie, but has anyone wanting cheap ally panniers/topbox thought of ally lp record flight cases, maplins do 'em for about 25 quid each. Not quite as big, or as tough, as your usual gsa cases, & can't fit a helmet in, but a good deal cheaper! I've got about 10 of them ( holding records!) and have been looking at them thinking 'Hmmmm?' :confused:
 


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