Zega Case simple reinforcement

[Bert]

I've noticed that after some 16,000 miles of bouncing around overloaded (who ever keeps to the 'no more than 10Kgs rule? ) plus and a few spills, the mounts are a bit loose. They are mounted on the cases using self tapping screws which I have now removed and replaced with 6mm bolts with locking nuts.
You just need to drill out (6mm bit) some of the rubber to let the bolts go in easy.
Feels more solid-

I have also been given to understand that the bottoms are only spot-welded- so I had my local 'Ali-welder- weld all-around- It's 'nul-points' en concours d'elegance but it works.

 

[Activmoto]

Bert,
I had the same problem with my Zega cases. The paint on the racks wears away and the cases also wear as I can see yours have on your 1st photo. I ended up cutting up some inner tube and placing it between the case and the rack. This works OK but not the best solution. I had the racks repainted but it did not last very long.
I can't see how your replacement bolts make any difference unless your self tappers were loose.
If I where to buy another set of cases I would make sure they can be ajusted to take up any wear. I see Metal Mule system has a means to adjust for wear.
One of mine also leaked around the base.
After this experience I would be inclined to go for soft luggage on any serious overland trips.
Steve

 

[Bert]

Hi Steve- yes, the self-tapping screws were rotating almost endlessly as lost most of their grip- not all but about 8 of them.

The welding reinforces the bottom of the case, bath-sealant takes care of any remaining wee internal gaps and those bolts now hold on! (hopefully!)
As for soft cases...I wouldn't! You can't lock them, they rip/burn/let water in and can't be bashed back into place after a fall. My 2p's worth!As for wear and tear..humm well, errr yes ! don't we all!

 

[Activmoto]

Your right about some of the drawbacks of soft panniers, but they are less inclined to brake legs, I had a minor fall and in the process of falling off put my foot down to have my leg trapped under the pannier, and felt lucky not to bust my knee.