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Old 08-03-2007, 09:20 AM   #1
baldwithglasses OP
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Location: East Atlanta Village, Atlanta, Georgia
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Ammo boxes for panniers?

There's no way I can afford fancy-pantsy aluminum panniers for my r65.

I CAN, however, afford to buy heavy-ass ammo boxes that were made for 40mm rounds.



These boxen measure 18 x 14 x 9 inches, so I'm thinking they'd be pretty darned handy for motorcycle luggage if I can find a way to mount 'em up to the old luggage rack.

Yes, they're heavy. They're strong and inexpensive and waterproof (that is, before mounting).

But boy, it'd be just lovely if I found a way to mount them quick-release style to the ol' R65.

Any suggestions?
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Old 08-03-2007, 04:56 PM   #2
bereahorn
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Penny tech panniers

I have a '92GSPD with factory cases and racks. While they are ok, I like the look and volume of the Mermite cans. Use the site's search engine and you'll come up with tons of info for the mermites. Anyhow,I bought two cans and have sand blasted the outside and gutted the inside. They weigh 10# each and if I crash them no big deal.
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Old 08-03-2007, 05:17 PM   #3
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Quote:
Originally Posted by bereahorn
I have a '92GSPD with factory cases and racks. While they are ok, I like the look and volume of the Mermite cans. Use the site's search engine and you'll come up with tons of info for the mermites. Anyhow,I bought two cans and have sand blasted the outside and gutted the inside. They weigh 10# each and if I crash them no big deal.
There's a thread in the Hall of Wisdom covering the Merimites. In that thread, there is a link to "Penny Tech Panniers". The thread's author in HoW does it a little differently than I did. Read both, and see what you think.
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Old 08-26-2009, 11:57 AM   #4
baldwithglasses OP
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Shoulda posted my solution way earlier...




...'cos I know folks want to make their own panniers and mounts on the cheeeeaaappp.

Raw pannier. Trimmed off some of the lid and back bracing (diagonal piece on back)

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Old 08-26-2009, 12:02 PM   #5
baldwithglasses OP
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Mounting hardware



Here's the makin's for your mounts: 3/8" hardened bolt, fender washers, cut-up hockey puck, neoprene-lined big-ass washer, and a knob (heh!).

baldwithglasses screwed with this post 08-27-2009 at 09:14 AM
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Old 08-26-2009, 12:06 PM   #6
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hardware installed, ready to load up!



This here's what you get when the box is painted and hardware installed.

Bottom mounts - little quarter sections of carved up hockey puck- permanantly mounted.

For mounting, I unscrew interior knobs, place the can mounts (which are on the cans!) in the luggage loop rack, fed in the mounts and bolts (all joined together as a stack unit), screw on the knob.
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Old 08-26-2009, 12:09 PM   #7
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Here's an inside view of the panniers. Note the twist knobs, and the white spray paint I used to help me see what I'm doing when I'm fumbling with the damned knobs.

After using this setup for over 30,000 miles, I'm hating this style knobs. Gotta find shorter, smoother profile knobs so they won't snag stuff I've got in the box.

Touratech knurled knuts? Naaahhh...
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Old 08-26-2009, 12:10 PM   #8
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...and here you go:

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Old 08-26-2009, 12:10 PM   #9
charliemik
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Cool stuff. Wish I could find pix of my ammo cans on my R80G/S. I've since sold them and bought Jesse's bags. I like the Jesse bags but, ultimately they're really not any better than the ammo cans. They worked fine and the Jesse's only feel maybe a couple of pounds lighter each. I bolted on a piece of 'L' bracket to hang them from the top of the stock rack and the used some electrical conduit clamps on the bottom w/ rubber washers to keep things dry. Not exactly 'quick release' but then, neither are the early vintage Jesse bags.
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Old 08-26-2009, 02:49 PM   #10
gs800er
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Ammo

Seems a great idea! Let me know the result ASAP as my shoulders are getting cut by my day sack!
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Old 08-26-2009, 06:01 PM   #11
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Dammit, bmwblake, I keep putting off writing you and your lovely bride a thank you note.

Hope you guys are well.

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Old 08-26-2009, 07:00 PM   #12
MZRider
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"Ammo boxes" without the weight

Only weigh 4 lbs. and cost $16 per: http://www.northerntool.com/webapp/w...3124_200153124
Might mount some up on my XT350.
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Old 08-27-2009, 08:25 AM   #13
charliemik
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Quote:
Originally Posted by MZRider
Only weigh 4 lbs. and cost $16 per: http://www.northerntool.com/webapp/w...3124_200153124
Might mount some up on my XT350.

Very nice find there MZR. These may be the ticket for penny tech panniers. The two biggest drawbacks to the steel ammo cans are weight and having to work around the diagonal reinforcement piece that can get in the way. These take care of both and they're dirt cheap.
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"Knobby tires and a GS do not a dirt bike make" - from Coco's sign-in book.


'81 R80G/S-SOLD (sad but I think the new owner is a really happy guy)
'81 R100RS
'96 R1100GS
'83 VW Westfalia (my 4 wheeled adventuremobile)
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Old 08-27-2009, 09:00 AM   #14
baldwithglasses OP
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Quote:
Originally Posted by charliemik
The two biggest drawbacks to the steel ammo cans are weight and having to work around the diagonal reinforcement piece that can get in the way.
Yup, they're heavy- even after some massaging with a grinder, the boxen weigh in at a none-too-stealthy 40 lbs, which includes mounting hardware and Campagnolo water bottle cage and "FYYFF" stickers.

That compares to the total ~23lbs total weight for unladen Jesse bags or Happy Trails bags.

As for the diagonal support, I used an angle grinder to take it off on one side of each of the boxes. I also used it to trim some of the excess lip material off can lids. I might have knocked off three pounds total off the boxes that way.

The other drawback that I have found is that they will not fit a full sized helmet, unlike some of the aluminum boxes.
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Old 08-27-2009, 06:26 AM   #15
bmwblake
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no note needed. we were glad to have you. you'd been radio silent on here for a while. glad to see you're doing well.


Quote:
Originally Posted by baldwithglasses
Dammit, bmwblake, I keep putting off writing you and your lovely bride a thank you note.

Hope you guys are well.
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