Build your own metal panniers on a budget !!

[Hamstein]

 

[kirky1298]

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?'

i may be wrong here , but i think those cases are made from plywood and skinned with very thin alloy hope this helps

 

[Hamstein]

hang on I'll go take a chisel to one and find out!

 

[Hamstein]

Yep, you're right, I've just ruined the lining on a perfectly good record case with me stanley knife and, yes, it at least has ply in the lid! Not willing to cut any more of it up! Also gave it a few kicks, and it seemed to hold up well, but who knows what would happen when water got into the ply. Still , it was a usefull thought!

 

[kirky1298]

dont worry bout it mate , i had that idea also , and it was pointed out to me by someone on this parish

 

[gbpot]

Anyone else started theirs?
I fancy trying a top-box as a start. Figured it might be more straight forward.
What's the dimensions of an average topbox?
Ta

 

[ogri-nic]

an average top box is big enough for what you want without being too big......

seriously, if you make inner bags then quick release isnt needed.... take your gear out in the bag. even the touringtwat kit you need to undo two nuts top take off.... instead of 4????

mind you, you get what you pay for. i have had alpos boxes for last 18 months - 2 years and am now getting a set of verns.--- having seen one of his which hit a tree at speed and survived!!!

( mine will be for sale soon with rails as will the wife's)

 

[Mac]

I have been thinking about adapting one of these http://www.samcases.co.uk/storm-cases/storm-range.htm but kirky's ally ones look within my abilities.

Damn, now i have more choices......

 

[simplysounds]

my home made panniers

here's mine. 20 litre per side. custom made mounts. made from stock flightcase trim from penn/swanflight uk. made from recycled 6mm impact resistant unbreakable solid plastic sheet (you can get 6mm plastic/nylon sheet on ebay). or use lightweight astroboard from swanflight (go half with someone - should do 4 panniers). lockable catches £9 a pair (ebay).

custom made swivel mounts made from nylon sheet using various size holesaws. tapped and screwed together. securing hooks made from 20mm thick nylon using hole saw, file, hacksaw.

here's a list of parts:

swanflight:
hinges: £0.63 x2
corners: £0.57 each (2 types used) x8 + x8
corner trim: £2.11 p/metre
lid maker: £4.02 p/metre
lid trim: £2.01 p/metre
top braces: £0.28 x 8

ebay:
nylon for securing hooks: £8
lockable catches: £9
rivets: £10 (16mm & 10mm x 4.8mm)

fully repairable. make great seat for cleaning/maintaining bike. i will be sealing inside with silicone but so far only very small amount of water inside after serious jet wash from all angles.

tools:

drill
vertical drill stand
hacksaw
stanley jet cut saw (to cut sheet) or jigsaw
hole saws
ruler
rivet gun

i'll post some pics if i can figure how to. tried to post pics as per faq how to but no joy.

http://s1095.photobucket.com/albums...implysounds/?action=view&current=P1010763.jpg
http://s1095.photobucket.com/albums...implysounds/?action=view&current=P1010762.jpg
http://s1095.photobucket.com/albums...implysounds/?action=view&current=P1010761.jpg
http://s1095.photobucket.com/albums...implysounds/?action=view&current=P1010785.jpg
http://s1095.photobucket.com/albums...implysounds/?action=view&current=P1010786.jpg