Zega Cases... what to do?

[smaytum]

I bought my Zega cases a year ago and for all the right reasons...
- they look good
- aluminium can be hammered back into shape
- they are waterproof
- the bars without panniers are discrete
- they are shaped for the bike (F800GS)

This is not my bike, but the cases are the same...


Last month, i went on a tough ride into Morocco. Plenty of piste work, sand, rivers etc and managed to drop the bike at least 5 times onto the panniers.

So here is the down side of these cases...
- they are badly pushed out of shape
- the seams at the base of the panniers are split so badly that i can poke my finger through
- the lids no longer fit
- the aluminium makes EVERYTHING black. Just touch them and our hands are black with aluminium dust

Humm. They need some serious repair work!!!

How should i fix the aluminium dust? Every gets black that touches these cases.

Rgrds,
Steve.

 

[andy leett]

Get them annodised or use inner bags.

 

[Cogs]

Mine are lined with neoprene ~3mm thick (a la BHT) and I have Karrimat pads cut to size and inserted inside the lids which double as seat pads when off the bike.

As for repairs, I've seriously deformed mine (and others sorry Henry ) before and found them easily straightenable with a cheap bench/woodworking clamp. Split seams are more difficult. I avoided re-welding by applying 25-30mm section angle aluminium to the outside edge with self tappers and lots of silicon. Not 100% waterproof but at least as strong as before.

CoGS

 

[Steve the Kiwi]

Mine are lined with neoprene ~3mm thick (a la BHT) and I have Karrimat pads cut to size and inserted inside the lids which double as seat pads when off the bike.

As for repairs, I've seriously deformed mine (and others sorry Henry ) before and found them easily straightenable with a cheap bench/woodworking clamp. Split seams are more difficult. I avoided re-welding by applying 25-30mm section angle aluminium to the outside edge with self tappers and lots of silicon. Not 100% waterproof but at least as strong as before.

CoGS

Sounds like the perverbial granddad's orignial Axe with three handles and two heads replaced....

 

[Cogs]

Yeah but, no but... a lot cheaper than new ones and every scar tells a story

See 'em at HU 2010 in the top field (with Zebra Bar stickers well earned )

CoGS

 

[Timolgra]

I wrecked a Zega pannier and managed a decent enough repair using a piece of wood inside the pannier which was a bit longer than the pannier width and a big hammer.

The split seams were just pop riveted and they've been fine ever since.

Use some sort of bag to prevent stuff getting black and a piece of foam as suggested in the bottom