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Old 03-19-2013, 12:40 AM   #12
Te Hopo OP
AKA Deanohit
 
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Joined: Sep 2007
Location: Picton, New Zealand
Oddometer: 1,141
Now on to luggage capacity, I have had soft bags in the past and had things taken by light fingered thieves, from now on I am sticking to hard locking cases.

Back at end of last year I rode down to visit a mate and needing some way to carry my gear so the search was on.
I can't afford the price of proper aluminum panniers and mounting racks so like usual I made some myself, keeping them as simple as possible.
Two black plastic jerry cans were sourced and the top was promptly cut off with my jig saw which left me with a good looking, tough seamless box 20L in capacity, these two plus my top box gives me 70L of lockable luggage space.

Some lids were made with sheet steel and aluminum angle.
Marked to cut the corner:


Ready to bend:


Glued and riveted to the sheet steel and hinges:


Some more flat stock aluminum was bent up to go from the grab handles to the pillion pegs and all bolted in place.

The rim of the lids was lined with some foam to make them water resistant and a locking spring latch is used to hold them closed.

Te Hopo screwed with this post 03-20-2013 at 02:31 AM
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