My probably over complicated way of getting TT Zega panniers onto the frames!
I had checked out the TT USA site for clues so I used some of the installation instructions from that and then bodged the rest:
First of all the indicators
12mm metal bar, drilled to accept indicator cables
Drilled and fitted a small grub screw to stop the bar moving
New indicator position!!
Easy! no cost!!
Firstly strapping the two panniers together and putting them onto the bike frame.
Then to bungee them into a very rough position
Then, the time consuming task of adjusting, adjusting and more adjusting.
I had to be over 10 foot away to get them lined up. I measured from the ground to bottom of the panniers several times and they just did not look straight..
This was the point when I realised that I would not be able to get the lid off the right hand side pannier due to the metal mule topbox....
So, lowered them both as far as I could and daisy chained some zip ties and then tied off both panniers.
Again, checking every time I moved them to make sure they were as straight as I could make them.
Then onto the marking!
Frames were traced onto old boxes which I then slid in between the pannier and frame.
I'd seen the bloke use a magic marker but thought this would be easier off the bike.
I drew round the pucks marking the points at which the screws would then go into the pucks.
Again, another double triple check to see if they were in line then the cardboard was taped to the panner.
The pucks were then put onto the card and every hole marked. I centered the top 'locking bolt' hole between the four other holes.
All holes drillled and the big hole I drilled out with a step drill bit giving lots of room for the thing to turn
I then fitted all screws into the inside and started to attatch the pucks.
Then the first pannier was mounted! hurrah!!
I then lined up the LHS pannier again and slid in the second piece of card
Much easier to do due to the extra space for the baffle! so the puck marking was simple and the template taped down.
All pucks lined up and all holes drilled
All lined up! took a couple of hours in total, including fitting the rack - most of this time was trying to line them up though! with the mule top box it did restrict me a fair bit!
Drilling took no time at all! I used a smaller bit then suggested so the screws bit into the ally and again into the pucks, felt nice and solid!
Then I fitted another obligatory tosser TT accessory. I love the bottles though! anyone know who actually makes them???
Straightened this pic so you have an idea from the front!!
They have just completed 350 miles today, loaded up and they didn't fall off so hopefully they'll be fine!
I'd say a couple of people would be the best way of fitting these, one to position and hold, one to mark, it would be alot quicker!
Also, being a locksmith I'd not bother with the cam locks, they are propper shite!! L&F type you can open with a paperclip. They are so small you only will get probably 3 wafers if that in them - a filing cabinet has about 5 and these open very quickly indeed.
The right side of the shackle is smaller diameter then the left (where the padlock can go) I'm going to drill the right side out and stick long shackled padlocks through both holes. Will reduce movement of the locks and have two anchor points on the shackle...so at least that wont move when the lid is being forced open.. Oh well, there is only so much you can do to protect your property!!
Hope this is of some use!!
Sid
