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How to protect your gear from turning black from Aluminum? How to protect your gear from turning black from Aluminum?
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Photo by Lois Pryce, schoolkids in Algeria

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and schoolkids in Algeria



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  #1  
Old 11 Apr 2021
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Join Date: Dec 2018
Location: Kincardine, ON, Canada
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How to protect your gear from turning black from Aluminum?
I have an aluminum top box, anything you put inside it gets blackened from the bare aluminum.

My attempts:

-Lined the inside with a self adhesive clear poly film which was about 6mil thick. This works but the the film wears through quickly from items bouncing in the box and didn't last.

-Spray painted a rubberized coating that is used for automotive applications. As with the film liner, it wears quickly and has started to peel where it has worn.

-My goto is an old helmet bag, I put items inside the bag to protect them and not worry about the bag. This works but you can't find things as quickly if they were just in the box.

Anyone have luck with a particular product to coat the inside of an aluminum box or pannier?

thanks
brian
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  #2  
Old 11 Apr 2021
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Maybe try a cheap closed-cell foam sleeping mat that you can get for a few bucks? Cut a bottom and a long piece that you use to line the walls. It's soft and chushioning, should do the trick!
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  #3  
Old 11 Apr 2021
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Location: Belper, uk, EUROPE
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Are you able to get it powder coated in a clear lacquer? If there are no plastic parts it should be doable - you may have to mask off certain parts. Beware of trying to powder coat over paint - it really doesn’t work and if you have any doubts then use a spray lacquer coating.
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  #4  
Old 12 Apr 2021
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Location: Oslo, Norway
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Lining aluminium panniers
I solved this problem by using thin strong mat, sold for car interiors. Cut to required shape and glued in place. make cut-outs for bolts. For the bottom I used a removable piece of an old sleeping mat on one side. The other bottom I used a thin plywood, with a finger hole, covered with a bit of car mat. this makes a false bottom, which has proved very useful for hiding that which must remain hidden. The whole job was much less hassle than you would think, and has worked very well.

Peter, in Oslo, and it's snowing today
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  #5  
Old 12 Apr 2021
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Great ideas. thank you all. I never considered making a false bottom, I can see it being useful.

thanks
brian
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  #6  
Old 13 Apr 2021
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Location: Belper, uk, EUROPE
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If you are gluing a false bottom in or spraying a clear lacquer or powder coating it then preparation is key - sorry, I couldn't resist the pun - and that means ensuring that the surface is grease and dust free - the results will last longer and will look better.

Alternatively use a bin bag or make some pannier liners with handles - these will also make unloading at a hotel / hostel a lot quicker and will reduce any issues if there is a slight leak in the pannier. Liners look a lot classier at reception than bin bags though!
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You will have to do without pocket handkerchiefs, and a great many other things, before we reach our journey's end, Bilbo Baggins. You were born to the rolling hills and little rivers of the Shire, but home is now behind you. The world is ahead.
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