Touratech Zega Recommended mounting puck locations

[samodeller]

Hi Guys, I finally managed to get a Set of Zega panniers. Touratech sell as set that is pre-drilled does anyone have the locations / co-ordinates of the Top two Pucks please. I just need the measurements for One side, preferable the top two, down from the lip of the pannier sealing rail.

 

[Gecko]

The way to get it right is to strap the panniers onto the rails using some webbing straps. Get everything in the exact right positions, don't forget the forward rake angle and levels across the whole width of the bike and then mark the puck positions from the outside - only then drill the holes.

 

[John Armstrong]

I think this is what you're after:

http://www.touratech-usa.com/media/xasmbc/pannier_instr.pdf

 

[Michael R1150GS Adventure]

The way to get it right is to strap the panniers onto the rails using some webbing straps. Get everything in the exact right positions, don't forget the forward rake angle and levels across the whole width of the bike and then mark the puck positions from the outside - only then drill the holes.

yep - this is what i got wrong and my boxes are pointing downwards - if you are stuck for the angle use the level rear of the bike as a guide - any steeper and they will foul the top box when you take the lids off (as mine do!)]

I still have my template from 4+ years ago... you want a copy?

 

[samodeller]

I had a look at those instructions, but I some how disagree with the 68mm minimum. I was wondering how I have them located at the moment is going to compare to Touratech actual holes they drill, on the pre-assembled set. For Eur40 Extra my brother should have just bought me those these thinking. Anyone have a set, that was pre-assembled what is there distance before I drill holes, i don't feel like messing a perfectly good set of new panniers

 

[Gecko]

You need to be carfeul using someone elses template because some have the panniers set higher (seat height) others have them lower (seat removed height) some have them horizontal some sloped forward ....1100 different to 1150 etc. Just be careful - use the straps and you can't really go wrong. because you use the puck as the template against the actual pannier frame on your actual bike.
I refitted a set from an Africa twin onto my 1100GS - I got some sheet alluminium to line the cases and glued and riveted it inside then redrilled the boxes using the strap method... 10 years on still fine

 

[Michael R1150GS Adventure]

its just the original touratech template supplied with my panniers when new
not a personalised one

think it has multi options on

 

[samodeller]

its just the original touratech template supplied with my panniers when new
not a personalised one

think it has multi options on

I have the template, Just doesn't tell me where touratech drills there Holes

 

[Michael R1150GS Adventure]

oh well (thanks for the offer of posting out the template by the way Michael! )

 

[samodeller]

oh well (thanks for the offer of posting out the template by the way Michael! )

I can scan it and email, it's a A3 page

 

[Dr Bones]

Whatever you do, use double sided tape to position the pucks, so that when you drill them you know they haven't moved.

When I did my panniers, I strapped them on the bike with webbing straps and supported the from below with a couple of wooden stools. Once I'd lined the panniers up with the rear subframe and checked they were level with each other, I stuck the pucks to the panniers with double sided tape. It was a simple job to then remove the panniers and drill the pucks in place.

Just take your time.

 

[samodeller]

Measuring up and fitting

Morning Gents,
So I didn't like the idea of Double side tape and screwing round with straps since, I am Building on the house there is limited space. So I found an easier way. Here are the steps.

I took the Touratech supplied templates and then put 4 strips of masking tape on the edges.
- went to the Frame and reverse rolled masking tap in 6 locations on the brackets, so you had the sticky side facing outwards.
- positioned the Paper template on the frame, and stuck it there. So now essentially you have a paper template on your pannier rack.
- took the Left hand pannier, because its lights worked out where I wanted it and the angle, this took all of two minutes and the pressed the 4 strips of masking tap into place. So now you have the Paper template stuck to the pannier.
- You just then remove the pannier, template attached.
- Took self centering punch and punched a Guide hole where the template showed.
- before taking it off, measured all the edges to position it up on the right hand Pannier. Word to the Wise, though the Left hand pannier rack sits higher then the right. So Add 5mm to the bottom measurements and 5mm of the Top, those on the side stay the same.

Once all the holes where drilled I made some safety cable for the Lids, since I don't want to loose them and have to import another lid. These are basically 2meters 2mm cable cut in 4 50cm strips, 2.5mm lug with 4mm hole X 4 and 2.5mm cable lug with 5mm X 4 all crimped together.

So there you have it.

I have the PDF scanned for the Touratech template, but cannot post attachments, they have my measurements on it too.

mail me at samodeller at gmail dot com if someone can upload the attachment that would be awesome