Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Equipping the Bike - what's the best gear?
Self made aluminum panniers & top case Self made aluminum panniers & top case
Register FAQ Calendar Today's Posts
Equipping the Bike - what's the best gear? Anything to do with the bikes equipment, saddlebags, etc. Questions on repairs and maintenance of the bike itself belong in the Brand Specific Tech Forums.
Photo by Andy Miller, UK, Taking a rest, Jokulsarlon, Iceland

I haven't been everywhere...
but it's on my list!


Photo by Andy Miller, UK,
Taking a rest,
Jokulsarlon, Iceland



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 31 Dec 2008
Registered Users
New on the HUBB
  
Join Date: Dec 2008
Posts: 15
Self made aluminum panniers & top case
Today morning I start bending and cutting the 14 ga (2.1mm) aluminum sheet. Tomorrow I will weld the boxes and finish them.











Reply With Quote
  #2  
Old 1 Jan 2009
Registered Users
New on the HUBB
  
Join Date: Dec 2008
Posts: 15
Yesterday size test & preview on the Vee:



Today welding and finish the panniers just left the top case and the rack for the weekend.
welding details:





Inside view:

Finish case:



[FONThe welder machine Miller Syncrowave 350 LX

Note I make a little mistake I welded the bottom pan in the top of the box #2 and that ruined my design the tow 90 angles should have been in the rear inner side.
The blueprints:



Happy New year!!!!
Reply With Quote
  #3  
Old 1 Jan 2009
Registered Users
Veteran HUBBer
  
Join Date: Feb 2007
Location: Denmark
Posts: 166
This is an interesting job.

Keep posting the pics as you go along. I am looking forward to seeing the finished project.

Happy New Year.

Steve
Reply With Quote
  #4  
Old 1 Jan 2009
Big Yellow Tractor's Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Jan 2008
Location: England
Posts: 649
An easy mistake to make :-(

You might as well make another two so you'll have a set to sell.
Reply With Quote
  #5  
Old 1 Jan 2009
Registered Users
New on the HUBB
  
Join Date: Dec 2008
Posts: 15
Quote:
Originally Posted by steveindenmark View Post
This is an interesting job.

Keep posting the pics as you go along. I am looking forward to seeing the finished project.

Happy New Year.

Steve
I will, just need to finish the top case and decide in which color I will adonize the boxes or maybe just the box covers.

Quote:
Originally Posted by Big Yellow Tractor View Post
An easy mistake to make :-(

You might as well make another two so you'll have a set to sell.
Yes I will make some other sets for sale under request and for fixing this little mistake I probably juts weld the other sides the same way and cut the top panel 15-20mm inside to get a a inner lip.
somthin like this:





Reply With Quote
  #6  
Old 7 Jan 2009
Registered Users
HUBB regular
  
Join Date: Nov 2007
Location: Western, Kentucky
Posts: 56
Thumbs up
How are the cans coming? I am VERY interested in the top case, I will be making one myself soon! Get busy! I would love to access to those tools.
Reply With Quote
  #7  
Old 10 Jan 2009
Registered Users
Veteran HUBBer
  
Join Date: Dec 2007
Location: Burton On Trent England
Posts: 134
have we got an emote for 'i hate you because you have way too many cool machines to play on'?
Reply With Quote
  #8  
Old 10 Jan 2009
Gold Member
Veteran HUBBer
  
Join Date: Oct 2008
Posts: 619
Garden Sheds
Man that's some shed you've got mate! All I've got is a bike cover and a socket set! I was proud of my new torque wrench till now. I'll keep quiet about it now though! Linzi.
Reply With Quote
  #9  
Old 26 Jan 2009
Registered Users
New on the HUBB
  
Join Date: Dec 2008
Posts: 15
Thanks for all comments, feedbacks and advises.
I finished the panniers and the top cases last week and decide to did a fast 1K road test on MX. Hwy 200 coast road . The panniers are sarongs, quite and waterproof.
I also did a extreme close sand inspection and the pannier (right side) didn't bent or broke :thumbsu:

here some photos:





Reply With Quote
  #10  
Old 27 Jan 2009
Registered Users
Veteran HUBBer
  
Join Date: Sep 2004
Location: Estonia
Posts: 351
Wow, that is a lot of storage. How much is total volume in liters?

How about replacing big top box with a roll bag for lower center of gravity? I guess handling of the bike will be much better. I'm sure you'll make next ones smaller.
Reply With Quote
  #11  
Old 27 Jan 2009
Registered Users
HUBB regular
  
Join Date: Dec 2008
Location: Phnom Penh, Cambodia
Posts: 33
These are really nice boxes.

I would like to look at the attachments that you are using. do you have pictures? are they slung or bolted on or both?

I would like to get something like this made in a developing country, rather than dragging them along with me on the plane. In the absence of 2.1mm ali and facilities to weld it, what thickness of steel would give the same strength? I guess at least 1-1.5mm. I would reduce the depth to keep the weight down, of course, they would need to be painted inside and out too if using steel. Another option would be to use thinner gauge ali and rivets and possibly ribs for strength.
Reply With Quote
  #12  
Old 27 Jan 2009
Registered Users
New on the HUBB
  
Join Date: Dec 2008
Posts: 15
Quote:
Originally Posted by Rebaseonu View Post
Wow, that is a lot of storage. How much is total volume in liters?

How about replacing big top box with a roll bag for lower center of gravity? I guess handling of the bike will be much better. I'm sure you'll make next ones smaller.
The panniers are 45L each and the top case is a little biger I guess 45-50L

Quote:
Originally Posted by steamerstimpson View Post
These are really nice boxes.

I would like to look at the attachments that you are using. do you have pictures? are they slung or bolted on or both?

I would like to get something like this made in a developing country, rather than dragging them along with me on the plane. In the absence of 2.1mm ali and facilities to weld it, what thickness of steel would give the same strength? I guess at least 1-1.5mm. I would reduce the depth to keep the weight down, of course, they would need to be painted inside and out too if using steel. Another option would be to use thinner gauge ali and rivets and possibly ribs for strength.
I made the mount system to be 2 parts 1 bolted on the panniers and one to the bike the panniers is like an omega and slice into a 2 rails on the bike part so you can remove the side cases fast and easy. I will post some photos latter.

About the steel boxes I'm not sure because of the weight and rust issues but if you need a cheap and a 1 time boxes I'm sure it is the way to go on a trancontinental trips.
Reply With Quote
  #13  
Old 3 Jan 2012
Registered Users
HUBB regular
  
Join Date: Dec 2011
Location: Tulsa, OK
Posts: 84
nice job on the boxes... now that's a large top box!
__________________
R90S, R80G/S PD
Reply With Quote
Reply

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
For Sale: Aluminum Panniers & KLR Rack NateDenay TRAVEL Equipment for Sale / Wanted 5 18 Nov 2007 04:45
Home made top case - secure and lock? Wheelie Equipment Reviews 12 28 Feb 2006 18:08
Aluminum Panniers as Check In Luggage liketoride2 Trip Transport 7 30 Mar 2005 02:37
Wanted: Aluminum Panniers StephenRivett TRAVEL Equipment for Sale / Wanted 0 23 Feb 2004 06:36

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

ALL Dates subject to change.

2025 Confirmed Events:

  • Virginia: April 24-27 2025
  • Queensland is back! May 2-4 2025
  • Germany Summer: May 29-June 1 2025
  • CanWest: July 10-13 2025
  • Switzerland: Date TBC
  • Ecuador: Date TBC
  • Romania: Date TBC
  • Austria: Sept. 11-14
  • California: September 18-21
  • France: September 19-21 2025
  • Germany Autumn: Oct 30-Nov 2 2025

Add yourself to the Updates List for each event!

Questions about an event? Ask here

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 05:39.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top