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Old 10-26-2006, 09:09 AM   #1
GPS_Jon OP
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Touratech Pannier Puck

I didn't like the way the top mounts worked (on the inside hand nut) on my Touratech Panniers so I made a set of pucks out of marine board on my cnc mill to fix them. This is night and day better than their setup and only adds 3/16" to the width of the hand nut assembly. Even force is applied across the mating surfaces now. Water resistance should also be improved (not that they have ever leaked in the past). The puck sits in place and nothing has to be modified, simply put it between the hand nut and the pannier (remove loose washer under hand nut first).




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GPS_Jon screwed with this post 03-02-2012 at 01:34 PM Reason: Photo Update
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Old 10-26-2006, 09:10 AM   #2
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Puck In Place

I wanted a solution that distributed the clamping force over the entire mating surfaces of the hand nut instead of just at the wave washer in the middle. I believe this distribution of force relieves the stress where the washer was along with the four screws securing the black spacer.

NOTE: There is NO modification to your current system. The Pucks sit right in place on and around current mount. The washer and nut in picture is absolutely secure.

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Old 10-26-2006, 09:34 AM   #3
dlew
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Nice job. i'll take two sets.
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Old 10-26-2006, 12:35 PM   #4
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Nice job
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Old 10-26-2006, 03:19 PM   #5
DRTBYK
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+1 and I'll take a set myself...
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Old 10-26-2006, 03:28 PM   #6
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+2



sets
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Old 10-26-2006, 04:06 PM   #7
GPS_Jon OP
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Thanks for helping me put my mill to good use .
Jon

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Old 10-28-2006, 01:30 PM   #8
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How to use:

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Old 11-03-2006, 10:48 AM   #9
DRTBYK
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Jon

Got the Puck's and you do good work sir.

I did discover that the Left Pannier Front Clamp Assy was a bit to close to the Pannier wall bend so I had to modify the Puck as you see in the photo so that it would lay flat. Easy job and now the Clamp Hand Nut fells the way it should have all along. By the way - I have the TT 41L Special Set Pannier's.

Thanks for taking on this project!

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Old 11-03-2006, 11:29 AM   #10
Pir8te
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Quote:
Originally Posted by GPS_Jon
I made these from scrap... but I can order a sheet of Starboard and make some more. That said I think $25 for 4 pucks (includes shipping) would work for me. It will help pay for my mill in the long run.
I will get on ordering a sheet and anyone who is interested please PM me. I will be out of town the end of next week but can start cranking them out around the 7th of Nov.

If anyone's got some other Touratech setup - I am not sure of fit but with details I can modify my drawings. It looks like all the Touratech kits use the same mounting hole dimensions/method though.
I have a 11gs and low pipe (dual 41L) pannier setup (18mm mounting frame tubes).

I didn't want to end up in the vendor forum but it looks like fate.

Jon
Would be intrested in a set
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Old 11-07-2006, 10:40 AM   #11
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Quote:
Originally Posted by DRTBYK
Jon

Got the Puck's and you do good work sir.

I did discover that the Left Pannier Front Clamp Assy was a bit to close to the Pannier wall bend so I had to modify the Puck as you see in the photo so that it would lay flat. Easy job and now the Clamp Hand Nut fells the way it should have all along. By the way - I have the TT 41L Special Set Pannier's.

Thanks for taking on this project!
I'm glad you like them. My bags do not have the clearance issue you have but it looks like you fixed yours right up. I assume that's as tight a fit in the corner as they could mount it.

The puck in the picture sits on the seam of the box. The material the puck is made of deforms around the seam and gives the hand nut a flat mating surface... another benefit.

Jon
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Old 11-07-2006, 10:57 AM   #12
dlew
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Great upgrade

I received mine from Jon last week and installed them straight away.

I hadn't felt the need for them before but now that I have them it makes total sense to have the intermediary between the hand nut and the pannier wall.

Nice work, Jon. They fit perfectly. I didn't have to alter them at all to fit my 41L special set on my 12GS.

I would prefer for them to stay tight to the pannier wall when I loosen the puck so I'm thinking of a way to keep them there. (I don't want to to tightne them up unaligned.) Perhaps just a dot of some kind of contact cement? Rubber cement?
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Old 11-07-2006, 12:17 PM   #13
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I have found that I now loosen the jam nut and then back the hand nut out just enough to get the clamp bar out of the slot. I then turn the clamp bar so it clears the frame and snug the hand nut back up (just enough to keep it in place).

The material is a polymer and finding a glue to stick to it might cost a little more than its worth. The marine store sells something but at $25 a tube I passed. The manufacture hints that none of them will work. Let me know if you find anything that does. I wouldn't use anything too messy that can't be removed easily.

Jon
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Old 11-07-2006, 01:15 PM   #14
Willi-P
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Hi GPS Jon!

Can I get a set of those pucks from you?

I see you're in Jax. Me too.
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Old 11-07-2006, 06:30 PM   #15
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Quote:
Originally Posted by Willi-P
Can I get a set of those pucks from you?

I see you're in Jax. Me too.
I have Pucks made and ready to go.

I sent you a PM...
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