If you keep the Vario panniers one solution is the special expanding Touratech bags that velcro and strap on the top. We used these last year and they were very useful, especially for things like waterproofs that may be needed quickly - but
The overall decision after last year's trip was the I did not like the Vario panniers anyway. The capacity is poor and made worse with the liners, the liners are essential as the side opening design is a pain to use without them unless they are removed from the bike to load/unload, when heavily loaded they flex a lot as they are only located at the top and halfway down one side and when loaded they could flex out of shape making them hard to lock.
I would not want to use the tops as a rack to carry things like tents as they won't take the weight.
Sold them on eBay (only lost about £50) and have fitted Touratech Zega.
- the frames are bomb proof, you could lift the bike from them.
- the two frames are braced together so no flexing
- the box capacity compared with the Varios is not much different on the spec but as they are rectangular the useful space is MUCH more
- the top loading is much better, quick and easy to get thing in and out and all the capacity can be used.
- using the lids as a rack is easy, great for items like tents.
- easy to add `bolt on' extras. I have a bottle rack on one for spare oil after a bottle inside a pannier coming open last year and damaging clothes. The other has a water container.
The other side
- Many think they look ugly and I suppose they do - but they seem to suit the bike well.
- Ditto the frames when the panniers are removed. I paid a bit extra for the grey frames and they look OK but rarely take off the panniers off anyway
- the bare aluminium finish marks easily. I started trying to polish it but now just leave it to go an overall grey. Use of the liner bags (pretty cheap) is essential as the aluminium can rub on contents.
- they look very wide but in practice are less than two inches wider than the bars (offset to the left) which is better than expanded Varios and is not really a problem
To start with I was a bit concerned by the loose fit lids (no hinges) but in use it is no problem and has advantages. I can just leave a lid off to carry things that are too long to get right in and when using the lids as a luggage rack it is easier to take them off to get to contents than have a heavy tent hanging on a hinge with the lid open.
When I bought them I looked at other, similar, kits such as Metal Mule. They can be supplied powder coated and have hinged lids but were much more expensive (and I prefer the loose lids anyway)
Final comment. Touratech has a reputation for slow delivery and I have had some problems in the past but I ordered by phone on a Friday and a courier delivered on the following Monday.
