Home Made ?25 Panniers

[Raf]

So after planning my 5000 mile trip around France and Spain i realised i would need a large set of panniers to cargo my equipment around.

I've been looking at all types of panniers. Hard and fabric types.

I decided the fabric type panniers would be no good for the two months i would be touring. I needed something strong, waterproof and robust.

So set to look around for a set of hard case type panniers, the detachable ones you see on BMW's and was completely shocked at the prices i was seeing. £400-£600 for a set of what are basically two styled suitcases and a rail? No thank you, not when my bike cost almost that price.

Anyway i set about building my own.

I went to various places to first find containers of the right size. Something strong, not too wide, and not to deep so that it would touch the exhaust. I looked at coolers (to wide) ammo boxes (To heavy) and other storage boxes. I ended up finding some perfect storage boxes in staples for £9 a peice. Only problem was that they where transparent.


https://img181.imageshack.us/img181/5712/image189.jpg
https://img99.imageshack.us/img99/4248/image190j.jpg

After finding the correct boxes, painting and varnishing them i needed to find a way to fix them onto the bike.

My original plan was to reinforce the inside of the box with a sheet of aluminium and bolting them to the rear frame which failed miserably since the frame was to low and it would mean they could also not easily be removed.

I instead went for the simple method and ended up fixing the two boxes together with some strong oak planks, which i took off an old deck chair. I also reinforced the underside of the lids with more oak instead of using bolts that would have ripped through the plasic lids with the weight.
https://img329.imageshack.us/img329/6605/p1000213.jpg
https://img229.imageshack.us/img229/3350/p1000212.jpg

I then just tidied it all up by placing some imitation leather which i used to resurface the seat of my nsr. A few handles were placed on either side to provide a place to attach budgies to hold extra baggage.

https://img74.imageshack.us/img74/1716/p1000210.jpg
https://img74.imageshack.us/img74/6421/p1000211.jpg
Added some reflectors which cost £1 for 10.
https://img230.imageshack.us/img230/305/p1000214.jpg
https://img230.imageshack.us/img230/8396/p1000215g.jpg
https://img72.imageshack.us/img72/6584/p1000216.jpg
https://img171.imageshack.us/img171/715/p1000217.jpg

And yes i do realise they are two cheap plastic boxes strapped to a bike but they did only cost around £25 and where made in a day
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BMW K1100 - BMW K100 - Triumph Sprint ST 955i - Suzuki GSX-R 600 - Suzuki DR 350 - Yamaha XV 750 - Honda CBR 600 FM - Yamaha XT 600 - Yamaha Rs 200 - Honda NSR 125

[iooi]

Nice job.

One thing though..

I would find some method of locking the lids to the bottoms. With the weight of the contents of the boxes and the constant bouncing around on the road, the clasps won't last long. All the weight is on two flimsy plastic handles.
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Just because my bike was A DIVVY, does not mean i am......

[ToGGoT]

Very nice!

I looked through a lot of ammo boxes with the same sort of thing in mind for my bike - in the end our tour was cancelled, so i pinched my brothers old saddle bags.

My only concerns would be security, obviously, and also, how solid are those boxes? Would they break/shatter if you dropped the bike on them?

Otherwise, thanks for the pics!

ToGGoT
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2005 BMW R1150R

[carlperkins00...]

looks good i think.
what you could have done is paint them silver then glue a few boltheads on them so they looked like heavy duty metal. lol.
you could always fill them with aload of heavy junk and then go for a quick ride on a bumpy road to see if they hold up.

[MarJay]

Is your exhaust touching one of the panniers at the end? If so I'd be worried about melting a hole in them. I am also concerned about the boxes becoming dislodged from the lids whilst riding ans someone mentioned.

Apart from that, I really admire your ingenuity!
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British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[Raf]

I've already thought about some of the things mentioned. The part of the exhaust that does touch does not get hot enough to melt the plastic. I drove around yesterday with the boxes fully loaded for an hour and the exhaust was barley warm. The tip and link pipe do get very hot but they don't make contact.

As for strength the boxes are very strong. Im not sure if they would shatter there quite bendy plastic. but if you crashed or dropped the bike im sure they would most likely break with enough force.

The passenger footpegs when folded in also seem to act like an additional lock. When folded in they push the boxes upwards which makes it impossible to remove them even with the lid handles down. I will however have them rachet tied on for extra security.

Oh and i forgot the mention. When you remove the panniers. They also double as a bench
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BMW K1100 - BMW K100 - Triumph Sprint ST 955i - Suzuki GSX-R 600 - Suzuki DR 350 - Yamaha XV 750 - Honda CBR 600 FM - Yamaha XT 600 - Yamaha Rs 200 - Honda NSR 125

[Feasty]

Loving the camera sticker on the back of the bike! lol.

Wonder if they're more likely to pull you with that on though?
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Previous: Aprilia Habana Retro 50cc (beauty), Yamaha SR125 (fell apart), Honda XR125 (nippy little commuter), Honda SLR650 (Geewhizz), Yamaha Diversion 900S (Smoooooth) written off courtesy of a stupid escaped horse.
(7 year gap), BMW F650 (Relaxing ride). Aprilia Caponord ETV1000 (Big and bold). Yamaha FZS600 (got me in trouble too quick!).
Current: Yamaha TDM 900 (Comfy, light but big, power when needed).

[Finglonga]

[map]

[Raf]

[carlperkins00...]

[Finglonga]

[Raf]

[blamchez]

Hey brilliant Blue Peter style panniers I'm very impressed and will attempt something of a similar style soon.

As people have already commented, I would maybe secure each box with a strap just incase you hit a stray badger on your travels!


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50cc honda ---> CG125 ---> 125cc jap scooter ---> NSR125 ---> NC30 ---> CB500 ---> ZX7R

[Pete.]

I don't like them. Looks too easy for the retaining handle to fail IMO and that could mean disaster to anyone following.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[iooi]

[Flip]

Sorry, but it won't last 5 mins and it looks gash. One fall on the trip and your panniers are f*cked.

10/10 for effort though.

[Raf]

Thanks for the comments guys.

[Pete.]

[Nipedley]

Actually he did

[Flip]

[Lone-Wolf]

[colin1]

with ratchet straps in place to stop the bottom bits falling out, they could work quite well

one other possible problem, is uv light can make plastic brittle, if its not designed to sit out in the sunlight, the paint may protect it.
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colin1 is officially faster than god

[funmonkee]

Cool, just a shame they are made from plastic
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**** Don't ride faster than your angel can fly Get this Free Space
The democratically elected Mod of the Scottish Section - The Peoples Choice[b]

[Raf]