So, would it be possible to use self-soldering copper joints with mild steel tubing? Or would some strange reaction occur (like mixing steel and aluminium)? That might be the simplest solution for the incapable-of-welding.
The perk to copper pipe is that it's easily available, soft enough to bend without tools, cuts easily and there are ready made joints available. If nothing else that makes it very useful for prototyping, more useful than the plastic conduit I've used in the past as it can actually bear some weight which means you can test hang, and even ride with, panniers.
Then once we're happy it shouldn't be too hard to take the copper and get a steel version welded up.
Chris: your image of the throw-over plastic rack...
...takes me right back to my square one and thoughts on semi-rigid panniers. Unfortunately I'm one of those people who can see something in their head, but really struggle to translate that into a sketch. I could make one, but draw it? Do you have any more info on it? Type of plastic used etc.?
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