My spin on the KLR Ammo Can Pannier

Discussion in 'The Garage' started by Dubl-A, Dec 3, 2011.

  1. Dubl-A

    Dubl-A SuckerDucker

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    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
    [​IMG]

    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
    [​IMG]

    Added a latch lock and used a jig saw and dremel to open one of the slots
    [​IMG]

    Setup a beefy support brace for the custom hinge setup
    [​IMG]

    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
    [​IMG]

    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 ?;>]--
    #1
  2. willys

    willys Long timer

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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.:freaky
    #2
  3. GreaseMonkey

    GreaseMonkey Preshrunk & Cottony

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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.
    #3
  4. Dubl-A

    Dubl-A SuckerDucker

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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 :wink:
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  5. Dubl-A

    Dubl-A SuckerDucker

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    Thanks Grease, I should have some pics up this week :dllama (what a funny animation lol)
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  6. JamesG

    JamesG Rabid Poster

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    Plus removing the interior insulation is a PITA.
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  7. willys

    willys Long timer

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    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!:freaky
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  8. Speedo66

    Speedo66 Transient

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  9. Artful

    Artful Mid-life crisis time

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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?
    #9
  10. willys

    willys Long timer

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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......:freaky
    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:freaky
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  11. Dubl-A

    Dubl-A SuckerDucker

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    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 :D
    #11
  12. Dubl-A

    Dubl-A SuckerDucker

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    Thanks Willys, Im glad to hear it. :clap
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  13. beergut

    beergut Thumper

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    Cant wait to see them finished. Im planning to do the same system on my '08! :freaky
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  14. scarysharkface

    scarysharkface 30-125

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    Somebody needs to get our military to use aluminum ammocans, asap.
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  15. Dubl-A

    Dubl-A SuckerDucker

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    They sure wouldnt be cheap nor readily available :lol3
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  16. Dubl-A

    Dubl-A SuckerDucker

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    Holler at me if you have any questions when you start :wink:
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  17. GreaseMonkey

    GreaseMonkey Preshrunk & Cottony

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    For starters, educate me on removing the diagonal stiffeners on the sides. Did you find a particular technique to work best?
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  18. Rafiki

    Rafiki Some Dude

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  19. Artful

    Artful Mid-life crisis time

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    They are moving to plastic ammo cans.
    25mm ammo can
    [​IMG]
    14 x 5 3/4 x 14 1/2"h., weighs 3 lbs.
    But no one had them at the gun show where I bought the 60mm Mortar can.
    Guy said the military now has orders to Crush/Destroy/Burn the surplus they used to sell. :eek1

    Aluminum Mermite cans were replaced with plastic containers after Vietnam.
    You can look at some of the commercial plastic boxes but not that water proof from what I'm seeing in reviews.
    #19
  20. Dubl-A

    Dubl-A SuckerDucker

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    I used a small pry bar, a hammer and a chisel.
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    The side, skinny ribs came off effortlessly, but the actual support brackets that hold the handle and the latch were a little beefier. I used a drill bit the same size as the weld and gently drilled through the top layer then chiseled away. Couple beers and patience worked perfect<o:p></o:p>

    :1drink
    #20