I want to make Custom luggage in the UK.. help!
 

I have NO DIY skills to speak of and as a result, need to employ someone else to help me.
I want to build my own panniers and top box with specific features.

I've got a 'plan', but need to talk to a welder perhaps? Buy a 3d printer?
I've no idea.

I've no idea about materials (Aluminium/plastic??), but I know sizes and what not.
I've got Givi rack at the moment and figured it'd be nice to use them as the rack for custom luggage.

Anyone know of anyone who does this kind of thing,
If I'm barking up the wrong tree, tell me too!

Thoughts?

IMHO, Wrong Tree!? :blushing:

What bike are you talking about doing custom set up for? Can you post pics of it with current set up? Can you discuss what has NOT worked for you? What has worked? Why?

What sort of RTW (or other) travel do you have in mind?
Are you on the right bike? Or going up another "wrong tree"?

What set ups have you tried previous, on other bikes or this bike?
(IE: soft throw over panniers with lightweight racks or hard panniers with BIG heavy racks that crack!)

What sort of trips have you made previous to test out various systems and theories?

"Custom" conjures up all sorts of visions ... some etherial ... some demonic.
:rofl:
Most everything you think you know has already been tried and failed. Most of what works is out there and much of it is "for sale" for many common travel bikes. Do you want to re-invent the wheel? Or just "improve" it? :eek3:

Provide some info, maybe others can make suggestions. :thumbup1:

I'm an engineer. I'll fall for it and be your design consultant. Based on your current criteria my chosen material would be recycled kebab wrapper. It is cheap and easily formed.

Joking aside, give us the design criteria and I'm sure you'll get some pointers.

Givi use plastic as for large numbers with compound curves injection moulding meets their needs. I doubt this project will run to tooling costs.

Leather is traditionally used for toughness and a match to shoe\horse furniture skills. Still a possible.

Aluminium can be brazed, riveted or bolted but the trade off is strength and the seal. Adhesives cost and need serious prep and test......

My next sidecar body might be wooden just as a way of trying out old aircraft technology.


Andy

I like that idea of wood for at least part of your side car. An older Surfer friend back in the 60's collected Morgan cars. He had 4 or 5 in various stages of resto. I remember being stunned to see the Morgan's wood floor, door panels and other bits out of wood. WOW! At 18 years old I thought I'd seen it all. :rofl: But thoese engineers could have used some modern help with gear boxes and electrics. bier
https://lh3.googleusercontent.com/-8...phead_1963.jpg
I'll never forget the Leather strap round the "Bonnett"! (Hood)

He said Wood was great ... no squeaks or rattles. A bit heavy perhaps, but if restored well, would last for decades. Fantastic little cars. Only ever saw one of his Morgan's after full resto ... it ended up in a Car museum in Los Angeles. He also owned Messerschmitt cars. No idea what ever happened to the collection after he passed.

https://lh5.googleusercontent.com/-Q...06dd8-orig.jpg
Larry's was very similar to this version.

I can help you with welding / fabrication....

I have a capable workshop. There are also a few people and companies out there who can help you.

Where in the country are you ?

Customer Panniers
 

There is a chap called Roger who owns a comlany called ARD Cases - he made me a set of custom "pucks" to mount my luggage to a random fram I had lying around.

Very helpful Guy and good prices too. He runs his own fabricating business so should be able to help. Not sure if he has a webiste though doh

Costs?
 

If you pay someone to make them for you it will be extremely expensive. For a one off aluminum boxes would be cheapest- the more complex the shape you make it the more costly it will be (and possibly more fragile). Make what you want in cardboard first to get the bugs out. Things like taking it off and putting it back on can be worked out best using that cardboard model. You'll also get to realize the difficulties of making more complex shapes. There is an advertiser here how may help - Overland Solutions...

It will be far cheaper (and possibly more robust) to find something close and adapt it. Boxes in both plastic (eg pelican cases/otter boxes) or aluminum are available in various sizes. Try not to go with the boxes made for less demanding tasks .. things like aluminum photographic cases tend to fall apart on a motorcycle. If you want to use more of the space .. try two normal boxes of the appropriate sizes (large on the out side and the smaller one inside) and simply bolt them together.

Or you can develop your own DIY skills by making your own ... do the smallest/simplest one first so it is the cheapest one to make mistakes on.

Pelican cases make GREAT bike luggage. I was doing a location photo shoot of a Volvo semi once at the edge of a canyon. Dropped a Pelican case full of gear. It fell over nothing but rocks bouncing all the way for over 300 feet into a small pond. Took three hours to get to it but when we pulled it out and opened it up, everything inside was in perfect condition and bone dry!! Pelican stuff is truly outstanding!

I believe Gabe at Zen Overland makes customised versions of his luggage

ZEN Overland - Everything Adventure & Off Road

Gab is deffo your man... Say Ted sent you for a free sticker ;)