If you need catches etc for ally projects, PROTEX fasteners make the best range, we use them in our fabricating shop at work.
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http://www.protex.com/
Making Ally Panniers
- Thread starter Dennis the Menace
- Start date
Fanum
Toubab
Dennis..very neat rail.......looking good!!
The only obvious thing is the welded bracket....wouldn't it be possible to have welded that onto the underside of the rail rather than on top???
It'd look superb then.......
The only obvious thing is the welded bracket....wouldn't it be possible to have welded that onto the underside of the rail rather than on top???
It'd look superb then.......
st247
Registered user
The best looking mount i've seen sofar. Are you using any support at the base of the panniers?
On the picture showing the rear of the mount it looks to be quite a way from the chassis. I was wondering if thats going to cause problems with flex when your panniers are on. If it does, could you run a cross brace from one side to the other undeneath for some additional support? maybe bolted up under the rear end somewhere.
All very good though, i shall be watching with interest.
Are you using any support at the base of the panniers? On the picture showing the rear of the mount it looks to be quite a way from the chassis. I was wondering if thats going to cause problems with flex when your panniers are on. If it does, could you run a cross brace from one side to the other undeneath for some additional support? maybe bolted up under the rear end somewhere.
All very good though, i shall be watching with interest.
Yellow Peril
Registered user
Dennis see where you are going with it, looks like you have decided that BMW are not totally stupid and the pannier can be almost be completely supported at the top? You're further on than me I am still using thin ally to mock up the design. What thinkness stainless are you using? I am thinking of 8mm mild steel then having it powder coated , I am a bit worried about using ally mounts as it will get stress fractures. Will post pic next week of the mocked up mount, it is heading in the right direction and I don't mind admitting now I have picked more than one idea from BWM. 
the civil one
Registered user
the civil one
Registered user
Ready to mount {1150 Pictured}
Pic 2 is the Mounting Bracket ready to go.
You wouldnt believe the amnount of time involved in the Making of these
mounting brackets.
If either of you think i can be of any assistance , gimme a bell or
P.M. me.
In honesty if you can make a Box , i think it would be cheaper to Buy the
brackets / or even the Basis of the Brackets.
But then , i know , you wouldnt have done it yourself.
Pic 2 is the Mounting Bracket ready to go.
You wouldnt believe the amnount of time involved in the Making of these
mounting brackets.
If either of you think i can be of any assistance , gimme a bell or
P.M. me.
In honesty if you can make a Box , i think it would be cheaper to Buy the
brackets / or even the Basis of the Brackets.
But then , i know , you wouldnt have done it yourself.
Attachments
Yellow Peril
Registered user
Civil I have a quicky question you have said that you steel is 5mm but how wide do you have it? I am thinking approx 30mm?
Cheers
Shaun
Cheers
Shaun
the civil one
Registered user
Spot on
30MM , dont forget there is a steady Bar at the Rear as well.
Keeps everything from Swaying . Same Gauge of Steel.
30MM , dont forget there is a steady Bar at the Rear as well.
Keeps everything from Swaying . Same Gauge of Steel.
Yellow Peril
Registered user
Hoping to avoid that but have an idea if I should need it, after all the standard GS12's panniers don't use one.
Ps I emailled you the other day about you wally flaps and your computer did funny things any idea on pricing?
Ps I emailled you the other day about you wally flaps and your computer did funny things any idea on pricing?
I've emailed him twice about Wally flaps. I think he's gone Trappist!!ShaunT279 said:
Yellow Peril
Registered user
Ally Panniers
To Pukmeister
Protex Fastners, just what I am looking for.
Thanks
To Pukmeister
Protex Fastners, just what I am looking for.
Thanks
Ally Panniers
To Fanum
Thanks for your comment regarding bracket, underneath the bracket is a hole that hole lines up with the thread were I took the mounting mushroom? out of the bracket for the BMW panniers. As this tapped hole is on an angle i was struggling making two tappered washers, to mount the brackets securely. So the welded bracket covers plan "A" up, there's very little space underneath were the BMW mounting mushroom is to weld a bracket, but there is always a plan "C".
As you have made the comment, I agree it looks crap, but I was spending so much time trying to design and make something I realised I had not started on the panniers.
Although I have a Mig welder, I am able to stick together steel, but no way would I term it welding. So, trying to weld stainless steel or aluminium is out of the question. I have tried to make the panniers and brackets with as little welding as possible, by using adhesives/sealant, set screws and nuts.
Dennis
To Fanum
Thanks for your comment regarding bracket, underneath the bracket is a hole that hole lines up with the thread were I took the mounting mushroom? out of the bracket for the BMW panniers. As this tapped hole is on an angle i was struggling making two tappered washers, to mount the brackets securely. So the welded bracket covers plan "A" up, there's very little space underneath were the BMW mounting mushroom is to weld a bracket, but there is always a plan "C".
As you have made the comment, I agree it looks crap, but I was spending so much time trying to design and make something I realised I had not started on the panniers.
Although I have a Mig welder, I am able to stick together steel, but no way would I term it welding. So, trying to weld stainless steel or aluminium is out of the question. I have tried to make the panniers and brackets with as little welding as possible, by using adhesives/sealant, set screws and nuts.
Dennis
Ally Panniers
To Shaun T279
The stainless steel plate is 3mm thick. That's all they had in the scrap box. It is too thick and heavy, which is just what I didn't want. Made the first one out of aluminium and on folding it cracked (two thick, wrong type of aluminium)
Put a rule or a straight edge accross the brackets where the BM panniers mount you will find (they were on my bike) not level i.e. they will need shimming otherwise if you mount a straight plate onto the BM brackets you will be putting them under stress. Got some more pics of panniers mounted if you are interested.
Dennis
To Shaun T279
The stainless steel plate is 3mm thick. That's all they had in the scrap box. It is too thick and heavy, which is just what I didn't want. Made the first one out of aluminium and on folding it cracked (two thick, wrong type of aluminium)
Put a rule or a straight edge accross the brackets where the BM panniers mount you will find (they were on my bike) not level i.e. they will need shimming otherwise if you mount a straight plate onto the BM brackets you will be putting them under stress. Got some more pics of panniers mounted if you are interested.
Dennis
Yellow Peril
Registered user
I know what you mean Dennis I using a different system to you, will show a few pics later in the week you'll understand my idea then. But bear with be I am still at the mock up stage.
Dennis I just realized you are using the existing pannier front mount, very inventive I have copied it but not used it.
Are you putting in a rear cross member? To as civil put it "stop the swaying"?
Dennis I just realized you are using the existing pannier front mount, very inventive I have copied it but not used it.
Are you putting in a rear cross member? To as civil put it "stop the swaying"?
Yellow Peril
Registered user
Here we go Dennis progress so far, remember this is a design mock up not the finished article so the button head bolts holding the rail to the mount tabs will be gone. The rail it self will be of a thicker material probably 5mm or 8mm not decided yet. The black arrows are where the over centre latches will attach pannier to rail.
The mount to the frame on the bottom of the rail is designed just waiting on machine shop time to actually make it so using orginal OEM ones at the moment with very large spacers.
The mount to the frame on the bottom of the rail is designed just waiting on machine shop time to actually make it so using orginal OEM ones at the moment with very large spacers.
Attachments
Ally panniers
Hi Shaun
Some more pic's, more or less panniers finalised, mounting brackets still a question mark. Today I picked up a 5mm thick plate of carbon fibre. I wonder what I can make of that?
What do you think of my carbon fibre wally flaps "mark 4" (see pic 2) mak 1 - 3 got worn away.
Hi Shaun
Some more pic's, more or less panniers finalised, mounting brackets still a question mark. Today I picked up a 5mm thick plate of carbon fibre. I wonder what I can make of that?
What do you think of my carbon fibre wally flaps "mark 4" (see pic 2) mak 1 - 3 got worn away.
Looking good so far
Yellow Peril
Registered user
looking v good so far, as a suggestion have you thought of using an over centre latch (same as BWM) at the front of each box? Would help stop sway?
Ally panniers
Shaun
Already got two.
Put the boxes on a scale one with cut out weights 1kg less than BMW box.
One without cut out weights 1.5kg less.
Filled the box with exhaust cut out with water it holds 30 ltrs so I am guessing the full box should hold 40 ltrs. Don't know what BM boxes hold but, these boxes have more usable space.
I think your pannier mounts are more substancial and stronger than what I was aiming for. I am looking forward to viewing your pictures when the mounts are finished and the panniers mounted. As regards a cross piece to each pannier if necessary I will mount one. The BMW panniers are quite waggley is that a good thing or not.
When I paint the panniers I am going to use Hammerite special undercoat and then Hammerite top coat.
Anyone got any tips on how to apply. No doubt someone will say use a brush, or even a spray. I would like constructive comments as well as p**s take.
regards
Dennis
Shaun
Already got two.
Put the boxes on a scale one with cut out weights 1kg less than BMW box.
One without cut out weights 1.5kg less.
Filled the box with exhaust cut out with water it holds 30 ltrs so I am guessing the full box should hold 40 ltrs. Don't know what BM boxes hold but, these boxes have more usable space.
I think your pannier mounts are more substancial and stronger than what I was aiming for. I am looking forward to viewing your pictures when the mounts are finished and the panniers mounted. As regards a cross piece to each pannier if necessary I will mount one. The BMW panniers are quite waggley is that a good thing or not.
When I paint the panniers I am going to use Hammerite special undercoat and then Hammerite top coat.
Anyone got any tips on how to apply. No doubt someone will say use a brush, or even a spray. I would like constructive comments as well as p**s take.
regards
Dennis
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