In trying to keep the weight down, panniers version 1.0 are made of wood. The bottoms are 3/4", the rest is 1/4". I included some metal tabs to take the weight at the 3/4" on the bottom.
I nailed, screwed, glued, and reinforced them as much as possible.
Sexy, eh? They may well explode the first time I lay the bike down, but we'll see.
The first of several coats of paint:
Not many pictures of the lid construction, but it's 22 gauge sheet steel, folded over 1/4" at the edges and welded on the corners. The hinges and the latch are welded on as well (I like to weld).
On the bike. I also added some drawer pulls to the lid for handles / tie downs. The bungee is holding them on in the picture, but I added some thumb screws through to the mounts from the inside to hold them in place. Each pannier weighs about 7 pounds, versus 22 each for the ammo boxes.
It's about time to tear the bike down...