does size really matter...............

[welder8uk]

Been sizing up for making the molds for some panniers and top box. I placed freezer box (which just happened to be almost the same dimension as those I am going to). Trying to get the angles right and to get the measurements so that I dont deck the bottom of the panniers on every corner.

Question is, I want to make a topbox that will take a helmet , works out at about a 14" cuboid. But I have to say the size that the box needs to be is putting me off- is it worth making the top box capable of taking a helmet or should I go for the asthetic size and make a smaller one?

Picture of freezer box, not a bad size as it is, almost looks at home:




Steve

 

[welder8uk]

Not suite sure where the picture went, try again

 

[Deleted account W]

Where did you get the cool box, and do they do them in Madarin yellow

Looks ideal for transporting liquid refreshment to the BMF next week

 

[welder8uk]

Who needs computer modelling, this was to try and sort out the angles and the lowest the 'pannier' could go before hitting the deck before the crash bars.

 

[welder8uk]

unfortunatley I have a clue where the coolbox came from, we've had it for about 20yrs now, its a belter and the perfect size.

If you really wanted to, it would be an easy task to modify the frames to take and support the box. I did think of it, but I only have one box.

Steve

 

[Deleted account W]

Good idea, I like the way your going about designing them, keep us up to date with the progress

By the way that fence needs fixing or all the cattle will be out

 

[(RIP) Kaister]

Think about using bolts or a quick release method.

Straps are ok and strong enough, but untying granny knots is not fun.

 

[Fanum]

Oohh yeah...now this I like.....

Front edge....needs a taper under the box so you have more room to paddle the bike about without trapping your boot.....

Ouside edge, longditudinal....needs a taper as well......you can lean a GS further than you think


And make the top angle flat (level) when the bike's on its centre stand......I mounted my vernatechs to be flat and they're so much better like that.....eating off them, putting stuff on when camping, even just standing by the bike havinga cuppa...got to be flat.

 

[Fanum]

Where did you get the cool box, and do they do them in Madarin yellow

Yep...I've got one too....I use it as my bike cleaning seat outside.......

 

[welder8uk]

Never thought about mounting them level and using them as a rest. Trouble is I think it looks odd, have you got any piccies?

The molds I make will have the 60 deg angled edges on them, to all intents and purposes they will will look like Jesse/ Verns type designs. I am going to mold in vertical half round flutes on the outside edges of the boxes, although itll add to the rigidity of them - I am doing it because I think it'll look better asnd brake up the flat surfaces

After reading some of the posts on heat problems with panniers I think I am also going to allow for the mouting of a heat sheild as well.

The overall size will be about 15cm longer and higher than the picture shows. The top of the box will be almost level with the seat.

At the moment i am trying to decide wether to use aluminium plate or carbon fibre to stregthen the fibreglass at the mounting point and the lock and hinge positions. Probaly use ally for the mounting strengehens (cheap) and carbon fibre for the position of the hinges and lock (cos' I can mould it into the corners easily).

Other things I think I will do is add some metal rings (like D rings) around the out side of the panniers to use as loops to fasten things to - like when you strap tents and sleeping bags on. I think I'll give some more thinking.

But I quite like the size of the cooler box, not sure wether bigger will be better in this case - or wether it will just let me over load them

Before anyone mentions it, hopefully the house will allbe one colour by the ned of the summer, as for the weeds - they'll die off in Oct, the fence will only brake again, the bike will only get dirty if I clean it, the grass will only grow again if I cut it (I usually lock the geese in there for week, they soon eat it short) - lifes too short for all the things I want to do

Steve

 

[welder8uk]

For clips, Farnells do a natty quick releae clip http://www.farnell.com/datasheets/31507.pdf

and still using this to the clips on the bottom of the givvi racks, itll give a very sevure and quick release system.

Im not planning to use the coolbox or the straps, it was just to give me a 'mockup' to work from.

Steve

 

[Fanum]

After reading some of the posts on heat problems with panniers I think I am also going to allow for the mouting of a heat sheild as well.

Here's an idea for you then......

Don't bother with a cut-out, heat shield etc, that's expensive, laborious and heavy.....

Instead, (and at an extra charge because it'll actually be cheaper by a long way for you), include an exhaust lowering kit.....then both sides can be identical in size, you'll have no worries about heat and it'll make it a lot easier to make the boxes themselves.

Yep, I do have pics....can't find them now but I'll dig them out....PM me to remind me after the weekend if they don't appear here by then

Best of luck

Bill

 

[welder8uk]

I did think of lowering the exhaust, but the racks that are already on the bike are offset diferently on the left compared to right hand side. Theres approx 40mm diffence from the centre line of the bike to the edge of each rack on the bike- did that make sense?

So to a certain extent I am abit comitted for some of the design unless I change a racks as well. Givent hat there is nothing wrong with the racks I have to use the Givvi racks, I dont hitnk that I will have to change anything on them othe than take the top lock/ clip off the frame

When I get the molds done Ill post a picture, I am basically using one mold for both panniers, but the inside of the LHS side pannier will need another piece to 'clip ' in to give me the cutout on the finished pannier

At first I thought it would be pain to do the mold with a cutout, but its actually a very simple solution - I like simple soultions
Molds dont take that long to make and theyre cheap, most of the molds will be made out of that cheap white melamine board. Works a treat and you dont have to spend hours finishing and sanding the wood smooth.

The other option was to make the panniers different sizes, would have meant probably 2 different molds because of the differences, which is just a bt of a ball ache. Main reason is I dont like the look of them from behind - also not sure of the balance of the bike when loaded (but I am sure you can get around that)

Steve

 

[MikeO]

Rather than a heatshield, I'd definitely go for a removeably exhaust extension (a la Touratech or Civil One) - it'll guarantee that the exhaust gases will exit harmlessly rather than possibly being diverted elsewhere to do damage (ie melting indicators etc).

Simple fabrication, effective and, if it's removeable when the panniers aren't mounted, won't be too painful to look at.

Mike

 

[welder8uk]

Good call Mike, I dont know if the photo is going to show it but my number plate is already melting and it is a fair distance from where the paniers would be:

Steve

 

[welder8uk]

Fanum, tried putting the 'pannier mockup' on level, it looks alright. I though it would look unusual, but it doesnt, so level it is.

Do you think I should mould cup holders into the, or will the cups just blow away when I dirve off

 

[Deleted account W]

I'd like mine level, good idea Fanum

 

[(RIP) Kaister]

try using the centre stand for starters

 

[Fanum]

It just makes the silly things like putting ear plugs in (and leaving the second on top of a flat surface) mucheasier....plus like I said, you then get a table for eating, putting beer cans on etc etc.