Drilled holes in Tusk panniers, now need to close them up

Discussion in 'The Garage' started by ChopperCharles, May 17, 2018.

  1. ChopperCharles

    ChopperCharles Long timer

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    I drilled holes in my tusk panniers to mount them to the OEM luggage racks for my SCR950. After a few hundred miles, I wasn't happy with that setup. I wanted quick-release. So I purchased Tusk pannier racks for a DR650, cut off all the attachment points, and am welding them onto my OEM brackets.

    So... how do I seal up the holes I made in the aluminum panniers? I don't think braizing is necessary, as my only concern is for brief immersion during a stream crossing, and water ingress from the tire slash. (Two of the holes are right at the bottom). I know duct tape will work, but I'm hoping for something a little more... permanent. Some kind of adhesive bandage maybe? Epoxy a thin piece of aluminum over the hole? Open to ideas here.

    Charles.
    #1
  2. DirtyOldMan

    DirtyOldMan Long timer

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    That real duct tape, the aluminum kind you pull the paper backing off is pretty dang stout. Clean where you’re gonna stick it with an alcohol pad. On stuff that has a bit of thickness to it 1/8” or so, I put tape on the outside, squirt a little dab of silicone in the hole and then a piece of tape on the inside.

    JB weld works good too.
    #2
  3. Eatmore Mudd

    Eatmore Mudd Mischief on wheels.

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    Go down to the nearest airport or airfield and ask someone to put flush fit rivits in those holes.
    Water proof, looks good and shouldn't cost you more than a beer.
    #3
  4. mitchntx

    mitchntx Visit The wick in Seattle

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  5. Mercury264

    Mercury264 Once you go Triple...

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    Duct tape on the inside, fill hole with silicon caulk, put a sticker over the hole.
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  6. manstache

    manstache Jed

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    I'd cut out a thin piece of aluminum about the thickness of a soda can and JB weld it on over each hole from the inside. It would be permanent and the JB weld would also fill in the hole and can be sanded smooth.
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  7. Widgeon23

    Widgeon23 Uneasy Rider

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    What are the hole dimensions?
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  8. Maggot12

    Maggot12 U'mmmm yeaah!!

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    Many ways to skin this cat. You can put a small screw and nut, silicon on both ends before tightening.

    I used "well nuts" on my kayak a few days ago, so those would work for your application.

    The idea above of inside duct tape, silicon hole and a decal covering the holes from the outside is probably the least of all efforts with no tools.

    The jb welding of a small plate over them would work too.
    #8
  9. anotherguy

    anotherguy unsympathetic

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  10. ChopperCharles

    ChopperCharles Long timer

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    Push in plugs are a good idea, as are the rivets and the aluminum tape. Holes are big enough for an M10 bolt. One of them for an M12.

    Charles.
    #10
  11. phreakingeek

    phreakingeek adventurer

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    it it were me, i would want the inside as smooth as possible. My gear gets worn enough just from vibrations as I ride, I dont want to introduce any extra places that would induce wearing holes in my bags/tent/mattress.

    I'd probably go with the aluminum can and silicone patch method...or black duct tape. I've had that Gorilla brand duct tape over a couple of other panels on my bike for several years now and still good to go.
    #11
  12. Widgeon23

    Widgeon23 Uneasy Rider

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    When/if you install them, use some liquid electrical tape on the center rim. Flexible, watertight, but if you need to remove at some point it will break free easier than caulking. I use this method on watertight light fixtures.
    #12
  13. Bounder

    Bounder ExternallyDisplaced

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    I'd go with some Sugru, Its pretty tough stuff. Has other uses as well.
    https://sugru.com/
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  14. Widgeon23

    Widgeon23 Uneasy Rider

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    That looks pretty neat!
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  15. Bounder

    Bounder ExternallyDisplaced

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    It is pretty amazing stuff, uses are limited only by your imagination.
    I have a multipack of it in the fridge, I have used it to fix all kinds of things.
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  16. Widgeon23

    Widgeon23 Uneasy Rider

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    The only thing about it is the price. A good tube of silicone caulking is around $3. Liquid etape is $2. I will try it out though.

    It seems like a perfect fit for the op's needs though; if it comes in black. <-- edit, it does
    #16
  17. MrBob

    MrBob Curiouser and curiouser

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    This. Won't scratch pannier contents and should seal well. If necessary, alter the holes to fit the plugs.
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  18. shovelstrokeed

    shovelstrokeed Long timer

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    Look up 6061.com on U-tube. They have an excellent video on filling holes using TIG. Might be extreme for this application but would be the most permanent of repairs.
    #18
  19. Project84

    Project84 I can haz adventure?

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    I'd use aluminum sheet and gutter adhesive. I use gutter adhesive at work in place of nearly any glue/caulk cause it's tough as hell and holds up well to water exposure, obviously.
    #19
  20. sleazy rider

    sleazy rider Retired

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    TIG weld 'em shut. Screw all the patch and plug stuff. Do it right, do it once and be done.
    #20