If your looking for a good sealant, i would go to a shop that supplies nautical gear, like a marine shop. I use a product called Sikoflex, less expensive than what you were describing and nearly bomb-proof.

Hey Alex!

Very cool looking boxes , & guys very good support too. Cant wait to see the final results! How do you attach the box with the rack?

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I've had a mate make me up a set of panniers but our first attempt at creating a good fastening system to the rack / bike failed miserably.
What type of system are people using to attach the cases to the racks?

was going to ask the same question.... how to fasten the box to the rack?

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You can buy the pucks and racks from Touratech. Attach any box! Racks can become VERY complicated to build, especially if the boxes are quick detachable.

Brilliant, thanks. KIS- I like it.

Keeping it simple, I was thinking about 3 or 4 of these (2 at the top +2 at the bottom or 2 top +1 bottom, I will see), they are shed door hinges:





attached to the pannier this way they will work as "hooks"
The gap between the pin and the plate is 1cm, I will build a frame from (hollow) iron bars with a rectangular section of 1cm x 2cm.





Here is a pic of the very first approach to the issue of calculating the frame's shape, note the string and hinge temporarily attached with mask tape:





I will first make a rectangular sub-frame where the pannier will hook on then I will build the rest of the frame around this first one.

A further idea: making the sub-frame a bit wider than the actual pannier with some dents on the top bar I will be able to chose the position where the panniers will stay being able to slide them toward the back of the bike in case I will need carry a pillion or to the front if I feel like re-organising the balance/weight for a different riding style? It sounds like a nice idea but not sure how useful it would be.

Last thing: to secure the panniers I may use one or two latches (like closet or toilet sliding latches, eventually with a small lock) at the bottom or at the sides next to the "hooks".
I probably want the latches to be a bit weak but not too much, they will have to withstand the impact if the bike falls from the central stand but they will have to break setting the panniers free in case of a serious fall at speed, what is your opinion? In this case both the bike and the boxes (and the rider too...) will have more chances to survive? Or shall I make everything strong and solid? This way I am afraid the motorbike frame will bend...

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Hello all,
I have completed the alu panniers, I have posted some pics plus text on a webpage although the page is not complete, I will upload the rest of the pictures and add some more details once I have finished the rack hopefully by the weekend, as a preview:

rtw.xtz660 - Home made aluminium boxes

Let me know if something is missing (...please somebody check the grammar.....!!!!).

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Checked your website, nice stuff!! very detail, love it! gonna have a new hobby soon.....

got to go take my mom to hospital now....

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Hi All, Just found this wilst looking for a air compesser, might be the start of a pair of home made panniers! size is based on the can... but weight?? go look in a store and ask....
Clarke - Jerry Can Vehicle Bracket - Trimmers & Brushcutters - Machine Mart
TDMalcolm

hello all,
I am in the process of welding the rack for the panniers, any suggestion on the position? I mean, I usually see in pics panniers like Touratech etc and they are quite high and pushed back on the tail, is there any reason for this?
I was thinking at a lower position and not so far off at the back (I will not carry anyone). Is there something I havent considered or it's just to keep them away from the rider?
Any advice?

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a few things to consider.......Before final fixing.

Will you constantly bang legs/knees etc getting on or off bike?

Will they interfere with kickstarter ? (if one is fitted)

But the main thing, the most important thing to consider is will you be happy with them where they are? if yes, fix em on!

and by the way, they look the business!

good point

no kick starter by the way

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excellent thread, seems like a great idea making them ourselves. How much would the materials work out at ? Will the riveted joints withstand the sort of vibration you'd experience doing a trans africa trip? and also why not just get someone to weld the seams and save hassle of riveting, sealing, cutting corner bracings etc? The idea of using barrells looked good but I wouldn't like to be walking away and leaving them unattended for long in populated areas

I think riveted joints are more flexible than welded ones and in case of a damage you just rivet/screw them together but maybe this is me because I cannot weld aluminium...

IMO the weld shouldnt be on the edges because being the weld more rigid than the alu itself it may crack, probably a case made of a single alu sheet bent atthe four corners with only one joint falling in the middle would be optimal. then fit the bottom sheet somehow. But I will have to pay someone to do this.

materials worked out at about £100 with the possibility of saving something, there is the breakdown of the total cost at the end here: rtw.xtz660 - Home made aluminium boxes

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