Making Ally Panniers

Dennis the Menace · Jan 8, 2006

In the process of making ally panniers for a 1200 am using metal mule style i.e. in two halves with folded corners, but no frames as such. Am using same over centre compression levers as used by Jessies, want to keep the bike as standard as possible and as narrow as possible. I have cut out one side of the ally to suit silencer.
My problem is will 15mm clearance be enough (if not how much) around silencer to stop heat getting into the pannier, exhaust gases will exit through for want of a better word and inverted 'L' at the back of the pannier.
These panniers are not intended to be R.T.W. the farthest they are going this year is the Drac rally in June in Romania.

Vern · Jan 9, 2006

You want to be very careful.The 1200 runs incredibly hot,and I mean hot.Try putting a spacer plate there to sheild the inside of the pannier from the exhaust gas flow,but even that can get amazingly hot and melt stuff.If you get really stuck,give me a bell one evening and I'll see if I can be of any help.
01905 612705

Dennis the Menace · Jan 10, 2006

Ally panniers

Nice chatting with you Vern.

Will let you know what clearances were necessary and what heat resistant materials worked best.

ELIMINATOR · Jan 13, 2006

Don't Demon Tweeks do some professional type heat reflective material that may be suitable?

ELIMINATOR · Jan 13, 2006

http://www.ukgser.com/forums/showthread.php?t=62049

Look here.

Yellow Peril · Feb 23, 2006

Dennis hows progress on the panniers? You mention in the first post you where going to use over centre compression latchs like Jesse's , are you making these your self or have you sourced some other than Jesse's at 25 euro each?

I am playing around with panniers too trying to get the least amount of rubbish left on the bike as possible when no panniers. As I am still to find a pannier gives me all I want.

Dennis the Menace · Feb 23, 2006

Ally panniers

Should get exhaust side pannier back Friday, hopefully from welders. Over centre cam latch is part number sr5075 from plastics parts centre. The latch is black powder coated dye cast zinc. Phone 08457585070 they will send you one as a sample free of charge, I kid you not, I think they are about £8.00 or www.plastic-parts.co.uk. Will post photos at later stages.

Kind regards

Dennis

Vern · Feb 24, 2006

Full steam ahead then,give me a bell if you get stuck with anything :beerjug:

Yellow Peril · Feb 24, 2006

Thanks Dennis that helps me alot especially the expanded picture of the latch. Have they given you any idea how much loading the latch will carry?

cbritton · Feb 24, 2006

Having used the Jesses I think the catch system is a great idea. Why don't you use it Vern ?

Regards, Colin

jimbob · Feb 28, 2006

Dennis Crompton said:
In the process of making ally panniers for a 1200 am using metal mule style i.e. in two halves with folded corners, but no frames as such. Am using same over centre compression levers as used by Jessies, want to keep the bike as standard as possible and as narrow as possible. I have cut out one side of the ally to suit silencer.

Denis,

Bit of a cheek, but I'm thinking of getting some panniers made (dead cheap
to get ally fabricated out here). Where did u get your plans from, did u make
them up or copy them from some similar panniers...any chance of a look ??

Jimbob

Yellow Peril · Feb 28, 2006

Jim no doubt Dennis will reply in due course but seems the pannier is the easy bit, the mounting is less easy, being dependant on your requirements i.e mutt ugly ally tubes everywhere or slick hidden mounts that blend with bike like the originals.

jimbob · Feb 28, 2006

Mr Shaun

Cheers for the response. I have some rails on from the original
BMW system panniers (1100GS), but only one pannier (don't ask
- it wasn't me!). I was thinking of bodging some to fit them, in a
very neat unobtrusive way of course, using my one pannier as
some sort of pattern. Maybe pie in the sky, but the local migrant
workers are very skilled and produce some amazing stuff. Needless
to say, I don't want them to look shite

Jimbob

Yellow Peril · Feb 28, 2006

I would have thought that a skilled man should be able to copy the pannier you have got without to much of a problem.

Yellow Peril · Mar 1, 2006

Dennis hows the panniers going? I know you have used the over centre latches but what sort of mounting you got on the bike? Pic would be excellent when I have tidied up my solution we can compare

Dennis the Menace · Mar 1, 2006

Ally Panniers

Now quite sussed out how to post pictures, but trying

Regards

Dennis

Deleted account 220427002 · Mar 1, 2006

Dennis Crompton said:
Now quite sussed out how to post pictures, but trying

Regards

Dennis

read this then

http://www.ukgser.com/forums/showthread.php?t=32292

billy56 · Mar 2, 2006

I wish i was still working in a place i was a few years ago, I could have made anything. I was into Landrovers then (i had lost interest in bikes after my mate had got killed at a roadrace in 1990) I had full axcess to a pipe and sheet metal shop, I could get anything made and i had the skill to weld anything i needed, But alass no ships anymore, now i build buses

Dennis the Menace · Mar 3, 2006

Mounting Bracket/Alley Panniers Pictures

Don't think quite got the hang of these pictures they are a bit big. When panniers not on bike this is the only part visable, not quite ready for machining slots for the Jessie type cam fastners. At the moment just using fastners through the panniers with a nut a the back of the carrier plate as with anything there's always a plan B. Carrier is stainless steel and at the moment a bit to shiney. Comments please.

Regards

Dennis

LOLGEOFF · Mar 4, 2006

Nice big pictures.

Dosen't that rear wheel afect the geering a bit?

Making Ally Panniers

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