Universal Pannier Mounts for WingRack II

Discussion in 'The Garage' started by Joz, Mar 22, 2008.

  1. Joz

    Joz What could go wrong?

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    <o:p> </o:p> For those riders who own a bike for which a pannier and matching mounting kit are not available, here is a custom option.


    My bike is a 1990 Honda Transalp. Yes, Givi offers a complete mount kit with panniers but the bags just didn&#8217;t seem rugged or custom enough for my tastes. I also wanted a secure yet easily removable solution. Yes, I know the newer and more popular bike manufacturers and their aftermarket counterparts have this dialed in, but not all of us own those bikes.
    This thread documents my solution. While I used Caribou&#8217;s Pelican cases, this method could be used with other cases.


    In this example, Caribou (Pelican) cases are mounted on a Transalp.
    <o:p> </o:p>
    First, some keywords for those who may find this thread by searching: Caribou Cases, Pelican cases, Pelican 1550, Givi Wingrack, WingRack, Wingrack II, panniers, universal mount kit.
    <o:p> </o:p>
    Parts list:
    Caribou Cases $215 (including shipping)
    These are Pelican&#8217;s 1550 35 liter cases with Rodger&#8217;s customizations
    Givi Wingrack II kit (N101) & mounting kit (Y101) $215

    ½ inch square iron 3 feet long $6.00
    1 ¼ inch wide steel strap; 3 feet long; 2 pieces $10.00
    5 x .080mm bolts, 12mm long; 12 pieces $2.50
    5mm washers; 12 pieces $0.50
    5mm fiber lock nuts; 12 pieces $1.80
    8 x 1.25mm taper head bolts; 4 pieces $3.20
    8mm fiber lock nuts; 4 pieces $1.20
    <o:p> </o:p>
    Shop supplies:
    Dremel tool with lots of cutoff wheels
    Bench grinder
    Hand held drill with various metric bits
    Hacksaw
    Hammer & punch
    Bench vise
    17/64 drill bit
    8.0 x 1.25mm tap
    Patience
    <o:p> </o:p>
    #1
  2. Joz

    Joz What could go wrong?

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    The first step is to mount the Givi Wingrack and its mounting hardware per its included instructions.



    Next, I measured and cut the square tube to fit between the ribs on the back of the Caribou case.
    #2
  3. Joz

    Joz What could go wrong?

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    Measure as exactly as you can the distance between the lower mounting brackets of the Wingrack. Using basic math measure and mark the tube so the marks will be centered on the piece of square tubing. This will become the lower mounting plate for the case. Punch the marks and drill the tube.


    The pic shows the tube drilled and laying against the case.
    #3
  4. Joz

    Joz What could go wrong?

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    Drill only through one side of the square tubing. Start with a pilot hole, and then enlarge to 10mm. Visually align the lower plate with the lower mounts on the Wingrack.
    #4
  5. Joz

    Joz What could go wrong?

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    Now is where the fun comes in. Very carefully, align and hold the lower mounting plate in such a position that you can mark the ‘flare’ of the lower mounting bolts of the Wingrack onto the square tube. Obviously it is much safer to cut too little metal than too much. Notice the “Y” shape which should closely resemble the Y shape of the Wingrack lower mount points when viewed from above. Additionally, you’ll need to remove enough of the bottom of the mounting plate to slip the head of the mounting stud onto the lower mounting plate.
    You’ll want to test and retest fit the piece, carefully modifying the cut until it engages the mounting studs on the Wingrack.
    #5
  6. Joz

    Joz What could go wrong?

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    Make sure it is aligned properly!
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  7. Joz

    Joz What could go wrong?

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    Make sure each pin properly engages into the tube
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  8. Joz

    Joz What could go wrong?

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    Test fit the lower bracket
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  9. Joz

    Joz What could go wrong?

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    [FONT=&quot]To get a more positive engagement between the Wingrack studs and the square tube, I removed and ground the upper surface of the studs flat. [/FONT]
    #9
  10. Joz

    Joz What could go wrong?

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    Next we need to tackle the upper WingRack mount. It is a custom Give mount point.

    Remove the Wingrack upper mount/latch mechanism. Drill the upper mounting holes to 17/64 and tap for 8.0 x 1.25mm threads. Install the 8mm bolts and secure with their locknuts. Similar to the lower studs, grind the upper surfaces of these bolt heads flat.
    #10
  11. Joz

    Joz What could go wrong?

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    As previously outlined, cut the square tube, measure, mark, punch and drill the upper mount plate. Drill a pilot hole then drill to 9mm. Again, transfer, as exactly as possible, the taper of the upper mounting bolts (studs) to the upper mounting plate and use the dremel tool to cut the desired notches.
    #11
  12. Joz

    Joz What could go wrong?

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    [FONT=&quot]Now that you have the upper and lower mounting plates ready to mount to the bike, it is time to mount them to the cases. The first step is to mark, punch and drill pilot holes. If you don’t have a drill press it is best to do this on the side of the mounting plate that will be against the case. It is best to get the pilot hole in the center of the square tube. Drill all the way through both sides of the square tube using a 5mm drill bit. On the other side of the mounting plate, drill the mounting holes to 6.5mm (large enough for the bolt heads). The mounting bolts will be inserted from this side (larger holes). Repeat the same steps for the upper mounting plate.

    [/FONT] Cut the steel strap to the same length as the lower mounting bracket. Center the mounting bracket on the steel strap and, using the mounting bracket as the template, drill 5mm holes through the steel strap. The pic shows the bracket clamped to the steel strap.
    #12
  13. Joz

    Joz What could go wrong?

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    Now determine the optimal mounting position for the brackets on the cases that you are using. I mounted the lower bracket 4 inches from the bottom of the case for my bike but you will have to determine how you prefer them to ride (high or low). Use the lower bracket as the template, drill 5mm holes through the case, and insert bolts through the mounting brackets. Using the steel strap inside the case, pass the bolts through the steel strap, use washers and nuts on the bolts, tighten. Test fit on the bike.
    #13
  14. Joz

    Joz What could go wrong?

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    Mount the upper bracket onto the Wingrack and mark the case as it sits on the bike. As previously described; mark drill and mount the upper bracket onto the case. Test fit & admire your handy work.
    #14
  15. Joz

    Joz What could go wrong?

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    See if your work passes the 'kid seal of approval'
    #15
  16. Joz

    Joz What could go wrong?

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    Check it from behind
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  17. Joz

    Joz What could go wrong?

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    Of course, you have to decorate cases like these....
    #17
  18. Joz

    Joz What could go wrong?

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    And its not even dark yet! Still time to check out the other side.
    #18
  19. Joz

    Joz What could go wrong?

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    If you've noticed, currently there is no lock mechanism to keep the cases locked to the bike. I have ordered heavy duty keyed desk drawer locks and will post more pics once I get them in and mounted. So far, this setup has been very durable and reliable.
    A drill press would have ensured the holes were drilled perfectly, but I don't think it really matters that much. Close enough seems to work well enough here.

    I wanted something that I could easily get on and off the bike without the hassle I've seen other riders going through with some aftermarket options. I've put a few miles on this setup and it has been great - so far. I haven't yet done any severe off-roading with them.

    As mentioned in the beginning of this thread - these are meant to be universal mount brackets. You can use them with ammo cans or any other pannier.
    Hopefully I've inspired someone to give it a try and be creative. It feels really good knowing that you made something cool like this (well, untill they fall off anyway:lol3)
    #19
  20. soloyosh

    soloyosh Dad and husband

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    Nice work... look forward to the lock addition. Did you think about having Roger at Caribou sell you the locks they use for mounting and adapting those? That way you'd have one key.

    Again, nice work.

    Cheers
    Brett
    #20