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Old 12-03-2011, 09:37 AM   #1
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My spin on the KLR Ammo Can Pannier

Hey all,

Thought I'd share my variation of the ammo can pannier for our bikes. Since I have completed subframe strengthening, I started looking at the most common options and each time came up with the same conclusion that besides weight concern, I could make my own so I started looking at other home made options.

I have a pretty good general mechanical knowledge and decided to start working the the 20mm military surplus ammo can. I also did not want the typical complete removal of the lid rather a hinge system to allow one lock on one side and removal of most of the handle/supports. Check it out...

2 - Stock ammo cans shipped to my door for $79


Nearly complete prototype for my 09', Spent about $25 in hardware faulting trial and error more like $15 total needed and paint. stripped almost all the extra metal reinforcements to shave weight and generalize the look


Added a latch lock and used a jig saw and dremel to open one of the slots


Setup a beefy support brace for the custom hinge setup


Notice the whole support bracket is GONE, Used some steel brackets to create a sturdy exterior hinge setup. Used a rivet gun for everything to avoid nuts and bolts that could catch or be removed


I am planning on coating the exterior with bed liner and under coating the inside but have something cool up my sleeve I will post once its done ?;>]--
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Dubl-A screwed with this post 12-03-2011 at 09:49 AM
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Old 12-03-2011, 10:57 AM   #2
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They do look very good, but, real heavy too. Have you searched out mermite cans??? They are larger and extremely light in comparisn....just saying, sorry.
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Old 12-03-2011, 04:21 PM   #3
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Dubl-A I think you're doing an awesome job on those cans!

It will be nice to see them when they are finished and all mounted up.
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Old 12-03-2011, 04:53 PM   #4
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Originally Posted by willys View Post
They do look very good, but, real heavy too. Have you searched out mermite cans??? They are larger and extremely light in comparisn....just saying, sorry.
Thanks man, I had actually looked at the mermite cans but really did not like them visually. I guess a form -vs- function thing
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Old 12-03-2011, 04:55 PM   #5
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Dubl-A I think you're doing an awesome job on those cans!

It will be nice to see them when they are finished and all mounted up.
Thanks Grease, I should have some pics up this week (what a funny animation lol)
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Old 12-03-2011, 06:23 PM   #6
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Thanks man, I had actually looked at the mermite cans but really did not like them visually. I guess a form -vs- function thing
Plus removing the interior insulation is a PITA.
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Old 12-04-2011, 02:40 PM   #7
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Plus removing the interior insulation is a PITA.
Yes it is, but the rewards are great....lol

I agree the look of the smooth cans does look nice and they are by far stronger as well. I used to use them when I was Off-Roading in Jeeps.....loved them!
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Old 12-04-2011, 02:48 PM   #8
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Sportsmans Guide has the 20mm ammo cans for $20 each.

http://www.sportsmansguide.com/net/s...%20cans&eMode=
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Old 12-04-2011, 11:22 PM   #9
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How much weight did you get off the 16+ lb starting weight on 20mm can?

I looked for Mermite cans but none at SAR gunshow or at local surplus stores - Ebay prices were redicledorf for them.

I picked up a couple of 60mm Mortar cans (think very very tall 50 cal cans) 'cuz they only weigh like 7+ lbs each.

What kind of Rack are you making/using to mount your 20mm cans on? And what attachment method did you decide to go with?

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Old 12-05-2011, 06:34 AM   #10
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IMHO, the PackRat racks are by far the best and strongest racks on the market by far. Not too far price wise either. I bought them 5 years ago and have had zero issues with them and have even come off at 80 on the Dempster and they saved my skin and bike. Not to mention the mermites only were scratched afterwards. Nothing was bent or tweeked either! Amazing. Plus I tow a single wheeled trailer with them too! Like I said the strongest racks on the market, imho......
I just use 5 1/4 20 bolts to hold my cans on with. Yes not easily removeable for overnight in a motel if that is your need, but they don't come off or vibrate loose.....

Hope this helps
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Old 12-05-2011, 11:20 AM   #11
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Quote:
Originally Posted by Artful View Post
How much weight did you get off the 16+ lb starting weight on 20mm can?

I looked for Mermite cans but none at SAR gunshow or at local surplus stores - Ebay prices were redicledorf for them.

I picked up a couple of 60mm Mortar cans (think very very tall 50 cal cans) 'cuz they only weigh like 7+ lbs each.

What kind of Rack are you making/using to mount your 20mm cans on? And what attachment method did you decide to go with?
I did not weight them when I received them only heard they were 20lbs. I would guess I removed at least 2-3 pounds of metal so Im hoping its around 15-18lbs.

Im planning on the Packrat rack 225 shipped Im having a hard time justifying anything else.

I'll post up picks when Im done with the exterior
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Old 12-05-2011, 11:22 AM   #12
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Quote:
Originally Posted by willys View Post
IMHO, the PackRat racks are by far the best and strongest racks on the market by far. Not too far price wise either. I bought them 5 years ago and have had zero issues with them and have even come off at 80 on the Dempster and they saved my skin and bike. Not to mention the mermites only were scratched afterwards. Nothing was bent or tweeked either! Amazing. Plus I tow a single wheeled trailer with them too! Like I said the strongest racks on the market, imho......
I just use 5 1/4 20 bolts to hold my cans on with. Yes not easily removeable for overnight in a motel if that is your need, but they don't come off or vibrate loose.....

Hope this helps
Thanks Willys, Im glad to hear it.
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Old 12-05-2011, 12:24 PM   #13
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Cant wait to see them finished. Im planning to do the same system on my '08!
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Old 12-05-2011, 12:32 PM   #14
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Somebody needs to get our military to use aluminum ammocans, asap.
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Old 12-05-2011, 01:50 PM   #15
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Somebody needs to get our military to use aluminum ammocans, asap.
They sure wouldnt be cheap nor readily available
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