Hi folks, I just completed a project that I'm pretty proud of, my own homemade aluminum panniers! I've been longing for panniers for quite some time and I finally decided to stop my moaning and actually buy some aluminum sheet, steel tubing and pop rivets and start making something. First thing was welding together some sort of support for the panniers, a way to attach them to the bike. After careful consideration I finally came up with a design and started cutting and welding rectangular steel tubing. The tubing is 20x30x2mm mild steel. Here are some pictures of the process... Now that the supports were finished it was time to design the panniers. I finally went with 1.5mm aluminum stitched together with 15x20x2mm L-profile and 5mm pop rivets at c/c 50mm. I also put some sealing glue paste between the sheet and profile. The glue is gray in color and remains soft and flexible, It's pretty messy stuff to work with but will seal very well. The dimensions I came up with for the side panniers are 225x440x396mm and for the topbox I decided on 480x370x300mm. The width of the bike with panniers ended up being 960mm, I think there is a rule about not exceeding 1000mm in the EU. Regardless, I don't want my bike any wider than that. Here are some pictures of the pannier making process... As you can see by the pictures the glue is a really messy adventure. It comes off with the right solvent though so It's gonna be alright. I had initially planned to use 2mm aluminum sheet, but at the last moment I went with 1.5mm. I'm very glad I did because 2mm would just be silly thick. With all the rigidity from the L-profile, 1.5mm feels like bomb proof to me. I hope you like my pannier design, feel free to "copy and paste" to your bike. -Halli.