Thumper Club Forum

Club House => Chatter => Topic started by: guest18 on June 08, 2008, 12:28:51 AM

Title: Home made panniers
Post by: guest18 on June 08, 2008, 12:28:51 AM
I know Pat made a pair of panniers recently which he then decided were too large and sold on to another lucky thumperer...
If anyone else is feeling the need for a touratech style luggage system for a sensible price this site is well worth a look  8)
http://rtw.xtz660.googlepages.com/alluboxes
Title: Re: Home made panniers
Post by: johnr on June 08, 2008, 09:42:57 PM
prefer the prices on these!! ;D

http://www.moonshiners.org.uk/oildrumpanniers.htm
Title: Re: Home made panniers
Post by: guest18 on June 08, 2008, 09:56:13 PM
 ;D excellent stuff! I have to say in my defence I've already started work on blagging fitments and eyeing the scrap metal bin at work covetously  ;) ;D
Title: Re: Home made panniers
Post by: Steffan on June 11, 2008, 11:11:41 AM
Begs the question, exactly how much sh*t does one man need to carry? Given that he was off to what looks like north Africa so unlike travelling here (where you have to work on the upturned canoe principle) it beggars belief that he can need so much stuff. The longer I ride the more convinced I am that you need less than you think and whilst I am impressed with his DIY skill, I question the current obsession with Darr box copies - does the whole world want to look a certain "b-grade actor and his "special friend""?

Steffan
Title: Re: Home made panniers
Post by: Andy M on June 11, 2008, 11:43:28 AM
Not so keen on the rack. There didn't seem to be a cross brace. Having seen BMW plastic panniers leap off the rack (the square shape and silver colour didn't seem to help  ???), I'd want a proper box structure. Ok, the cross brace is a PITA when it comes to fixing a tyre, but isn't that better than having the racks swing on the three bolts until a hole turns into a crack?

Looking like the actor does seem to be an expanding trend. My Touratech boxes are now eight years old and like swiss cheese in the back after mounting on four bikes. They are more practical than anything else (you can sit on them for example), but if I didn't have a set I wouldn't buy them today. Before Metal mule brought out the rack for the Bonneville we were using throwovers. £100 decent soft bags and a stuff sack did what £400 of Touratech box would do anywhere within two weeks ride of the UK. Even RTW, I'd buy the rack, fabricate a top box the same shape as my split jerry can job and go soft on the rest.

Andy
Title: Re: Home made panniers
Post by: Steffan on June 11, 2008, 12:04:20 PM
Even RTW, I'd buy the rack, fabricate a top box the same shape as my split jerry can job and go soft on the rest.

Are you sure you're not just going soft generally  ;D  lol

Steffan
Title: Re: Home made panniers
Post by: guest18 on June 11, 2008, 05:31:12 PM
Begs the question, exactly how much sh*t does one man need to carry?....  ....does the whole world want to look a certain "b-grade actor and his "special friend""?

Steffan

I'd agree with the majority that he's carrying too much gear, a major hurdle in packing for a variety of outdoors pursuits is learning that just because you have a large luggage capability doesn't mean you have to use it all! I *can* hike with a full 125 litre bergen and extras, but I'd far far rather have it near empty  ;)

I'm in the process of building a set of ally boxes, not because I want to look like anyone else but because I've become hacked off with the limitations of commercially available soft panniers and I'm not handy enough with an industrial sewing machine to make my own (even if I did have access to one.) I also sometimes park the bike where I wouldn't leave soft luggage on and expect it to be there when I get back... :-\
That said I'm building them only about 15cm wide so they're a sensible size for the bike not like touratechs silver tea chests :o  ;)  ;D

All in all though I'd rather see people emulating the (in)famous Ewan and Charlie than trying to be a GP hero on the same roads my missus travels on!!
Title: Re: Home made panniers
Post by: guest18 on June 12, 2008, 08:30:46 PM
Not so keen on the rack. There didn't seem to be a cross brace...  ...I'd want a proper box structure. Ok, the cross brace is a PITA when it comes to fixing a tyre, but isn't that better than having the racks swing on the three bolts until a hole turns into a crack?...Andy

"After the successful test ride I decided to add an additional "U" to join the two basic frames at the back just behind the reg plate to improve the overall strength in case of a fall (it is not pictured here)."

Is that what you meant? If not what do you mean by "cross brace"? (not taking the mick this time! Serious Q...)
S  :)
Title: Re: Home made panniers
Post by: Andy M on June 13, 2008, 08:16:24 AM
The normal Touratech/Tesch/MM scheme is a length of tube bolted between the two frame across the area of the numberplate. It's bolted as you usually need to un-bolt to get the rear wheel out. The idea is that the box section of Frames and Cross Brace is stiffer than flat frame held at three points in the same plane (footpeg, shock mount, indicator type locations). The lack of flex prevents the three previously mentioned mounting points stretching their bolts or working them loose.

Not sure what the addition U is? If it means down one frame, across the numberplate, up the other frame it is the cross brace. I'd call it an H structure, but as you'll see from the spelling in half my posts i'm verging on the dyslexic at times anyway  :)

Andy
Title: Re: Home made panniers
Post by: guest18 on June 13, 2008, 03:53:19 PM
Yup, I understand, I reckon that's more or less what he's done.
(http://i219.photobucket.com/albums/cc167/alexpezzi/travel/DSCN2791.jpg)
Title: Re: Home made panniers
Post by: bullet350 on June 13, 2008, 07:01:40 PM

 you mentioned the cross brace being a PITA when removing the rear wheel. on the BMW, even the GS the exhaust has to be removed to get the back wheel out anyway. is it me or is that totally pathetic on a bike that's supposed to have RTW capability?

 i'm just experimenting with luggage on my cbr600 as i'm off to germany next weekend. so far the plan is:
 
 throw-overs
 large top box on rack.
 jerry can (in binbag) and tent on pillion seat.

sadly the tent is about 2 inches too long to fit in the top box.

also if the pillion seat was 2 inches longer i could strap another top box onto it.

bullet350
Title: Re: Home made panniers
Post by: Steffan on June 13, 2008, 07:50:17 PM
rear wheel on my GS came off like a car wheel; three or four nuts and off it came and no touching the exhaust.

Steffan

Title: Re: Home made panniers
Post by: trophydave on June 13, 2008, 08:09:19 PM

sadly the tent is about 2 inches too long to fit in the top box.

bullet350

Can you take the poles out and pack them separately?
Title: Re: Home made panniers
Post by: themoudie on June 13, 2008, 08:52:07 PM
Aye bullet350,

Keep the tent at your rear and jam the jerry between it and the top box. Wet tent sweating in top box, and all potential bulk and weight that high and aft sounds ??? to me. Also padding for your rump if you wrap the mat around the tent if you take one.

Main thing is have a safe trip and enjoy yursel'. ;D

Just packed up ready for Bob Mac, just light as only one night, but not much difference from normal but less clothes. Carton of UHT fully skimmed and old plastic 'takeaway' trays ready filled with the breakfast cereals and fruit. Enough energy to keep you going all day! ;)

Toodle pip, Bill.
Title: Re: Home made panniers
Post by: guest146 on June 14, 2008, 07:26:20 PM
I must say I am impressed with the workmanship in making these. He seems to have found every component he needed. I think I would run out of steam before it was finished but credit to him

Ken
Title: Re: Home made panniers
Post by: Andy M on June 15, 2008, 06:43:45 AM

 you mentioned the cross brace being a PITA when removing the rear wheel. on the BMW, even the GS the exhaust has to be removed to get the back wheel out anyway. is it me or is that totally pathetic on a bike that's supposed to have RTW capability?

 

Don't get me started. On the Triumph the rack needs to come off in one piece, then both silencers and pillion pegs  >:( Good news is that I can now do this in about 20 minutes flat (pun intended)  ;)

Did my dad's tyres yesterday and on the Guzzi it's one silencer and a shocker, but then you've got to raise the stand over a 2" drop to get the wheel out. That's a two man job  >:(

My R1100R was car like and is the model i'd point all designers towards. I guess the R1150 or R1200 has yet more style over function features? The only BMW's I'd entertain again are the F650 and R80. I've worked with CAN electrics and believe me, on that alone I wouldn't take an R1200 RTW without Ewan and Charlie's silent partners following with a spare in the van  :-X

Andy
Title: Re: Home made panniers
Post by: Steffan on June 15, 2008, 08:46:17 AM
My 1100GS was the same Andy, reminds me of a certain mobile phone company that used to follow the big cheese (when visiting from overseas HQ) would follow him about with a mobile mast in a van so he never lost coverage. OK for corporate bigwigs but not my idea of a bike adventure - give me cables and a tin of lube.

Steffan
Title: Re: Home made panniers
Post by: Richard on June 15, 2008, 09:21:56 AM

'Tin of Lube'....are we still on the subject here ?
Title: Re: Home made panniers
Post by: guest18 on June 15, 2008, 10:47:06 AM
I find these tales quite incredible  :o

Having to remove exhausts to change a wheel, (bad), or worse yet suspension components or subframe parts, (completely ridiculous)  ???
I can see having to remove a rear cross-brace as it is an aftermarket accessory and should only need four bolts and a couple of minutes (I intend using the same sized bolts as the chain adjustor so no extra tools required), but what you're describing sounds like a major design fault. It would be extremely poor design on a home built special, quite unbelievable on a supposedly professionally designed mass market vehicle  ???


 you mentioned the cross brace being a PITA when removing the rear wheel. on the BMW, even the GS the exhaust has to be removed to get the back wheel out anyway. is it me or is that totally pathetic on a bike that's supposed to have RTW capability?

 

Don't get me started. On the Triumph the rack needs to come off in one piece, then both silencers and pillion pegs  >:( Good news is that I can now do this in about 20 minutes flat (pun intended)  ;)

Did my dad's tyres yesterday and on the Guzzi it's one silencer and a shocker, but then you've got to raise the stand over a 2" drop to get the wheel out. That's a two man job  >:(
......
Title: Re: Home made panniers
Post by: squirrelciv on June 15, 2008, 07:08:00 PM


 It would be extremely poor design on a home built special, quite unbelievable on a supposedly professionally designed mass market vehicle  ???


Welcome to the modern world of motorcycle design. All to do with how it looks and nothing to do with how it works. To be fair, it was never designed with the home mechanic in mind, Most 'bikers' today, buy it, clean it, ride it on a sunny Sunday and get it serviced/fixed by the dealer. Jees i'm turning into a grumpy old biker >:(
Title: Re: Home made panniers
Post by: bullet350 on June 15, 2008, 07:43:59 PM
anyone removed the rear wheel from an enfield or qd BSA?

throw a few bricks under the centre stand (remember centre stands?).

remove small nut on end of axle and yank axle out.

the wheel drops to the ground leaving the drum brake and sprocket in place on the swingarm!

no readjusting the chain! in and out in a couple of minutes (nudge nudge wink wink).

ah the good old days!

bullet350
Title: Re: Home made panniers
Post by: Steffan on June 15, 2008, 07:48:21 PM
Yea, if only you could skip the bricks, ie if only the centrestand lifted one wheel rather than leaving both on the deck

Steffan
Title: Re: Home made panniers
Post by: 002 on June 15, 2008, 11:05:01 PM


 It would be extremely poor design on a home built special, quite unbelievable on a supposedly professionally designed mass market vehicle  ???


Welcome to the modern world of motorcycle design. All to do with how it looks and nothing to do with how it works. To be fair, it was never designed with the home mechanic in mind, Most 'bikers' today, buy it, clean it, ride it on a sunny Sunday and get it serviced/fixed by the dealer. Jees i'm turning into a grumpy old biker >:(

Dont start me on that one !!!!!!!
Working in a Dealership I come across them all !
Most cant adjust the clutch cable let alone their chain.
I have managed to upset quite a few customers by telling them what routine maitenance entails,and how often.


Jethro
Title: Re: Home made panniers
Post by: Steffan on June 16, 2008, 08:44:18 AM
The thing is Jethro. in some circles opening a conversation with F*&k off you &^%** is apt to cause some offence, especially if they think they are paying... it's a funny world.  ::)

Pat you are not alone - you grumpy old B*&#*$d  ;D

Steffan
Title: Re: Home made panniers
Post by: 002 on June 16, 2008, 09:55:10 PM
No !    I start with......

"Have you read your Handbook ? NO ! Then I'll Show You....ONCE!   Then YOU WILL Have to do it your F@*#ing Self 'cause I wont do it next time "


Quit pleasant,but straight to the point !  ;D


Jethro
Title: Re: Home made panniers
Post by: steveD on June 16, 2008, 10:19:52 PM
My attitude is slightly different as most of my customers haven't got a clue about the work that I do so if they ask for something really trivial or stupid I just get on with the job and do it then charge for it. When I was teaching I was paid to show pupils what to do, now that I am self employed customers will have to pay for my services and expertise, not for me to tell them how to do a job, I keep that info to myself! ;)
Title: Re: Home made panniers
Post by: guest18 on June 17, 2008, 12:37:31 PM
A pair of nice slim panniers now starting to take shape  :)
(http://farm4.static.flickr.com/3014/2587231262_10f1892866.jpg?v=0)

Of course I'm making mistakes as I go  :-[ (it's been a while since I did much fabrication!) but nothing insurmountable or expensive yet  ;) though I don't know how much longer my pop-riveter will survive the toughest rivet shanks I've ever come across  :o

The only bother so far is my usual suppliers have drawm a blank on catches for the lid, I was thinking of over centre, padlockable (yeah I know, new word lol) catches but no-one I can find seems to sell them  ??? Anyone know of a supplier? Or a better method of clamping (and locking) the lids to the boxes?

I reckon I'll go for simplicity and just use wingnuts (or nylocs if I go semi permanent) to mount the boxes to a frame, not really quick release, but secure and easy and rattle free, the KISS principle in action  ;D
Title: Re: Home made panniers
Post by: jules on June 17, 2008, 02:51:10 PM
SMUDGE TRY THIS PLACE FOR HANDLES AND OTHER HANDY STUFF
http://www.woolies-trim.co.uk/DEFAULT.ASPX
Title: Re: Home made panniers
Post by: guest18 on June 17, 2008, 04:18:58 PM
Cheers, will give them a go  8)
Title: Re: Home made panniers
Post by: Bruce on June 17, 2008, 04:43:19 PM
Smudge you could also try http://www.protex.com/ they sell a wide range of fastners ,re the panniers I had off Pat whilst riding near Poole in Dorset I managed to lose one of the lids so I have got to try and make a replacment.I was heading for the ferry to St Malo to get to the Triton Club of France rally it was one of the best weekends for years good warm weather lots of good food and wine.When I refit the lids I will use overcentre clips with a spring.
Title: Re: Home made panniers
Post by: guest18 on June 19, 2008, 09:22:44 PM
Catches arrived from Woolies today, not fitted yet but look just the job. Spent this evening drilling and rivetting when I should have been packing for the weekend  ;D boxes are now one good session away from being ready to start making a mounting frame I reckon  8) Unfortunately I have to work this weekend so I don't think I'll be able to finish the job in time for the TC rally  :( Ahh well, have booked the Friday off anyway and am looking forward to a nice gentle blat down the A7 A6 etc  ;D just praying for dry weather now!!  8)
Title: Re: Home made panniers
Post by: guest18 on June 23, 2008, 08:14:11 PM
Haha! They look like proper boxes now  8) 90% finished I just need to add catches to one and corners and lid seals to both. Most satisfying progress  ;D
(http://farm4.static.flickr.com/3004/2605405408_5fb88bafaa_m.jpg)

After that comes the much trickier bit of building a frame for them...
Title: Re: Home made panniers
Post by: steveD on June 23, 2008, 08:26:43 PM
They look pretty damn good, do you do contract work? the equivalent things would cost at least £200 for cheapies and £??????????????? for the stupidly expensive ones and I bet yours are more substantial from your write up and design. And yes the frames are the most difficult. Can't wait to see and get some ideas  ;)
Title: Re: Home made panniers
Post by: guest18 on June 24, 2008, 06:05:55 AM
Contract work?  :o I can barely find the time to do mine lol,  ;D I think by the time I've bought extra metal and fasteners for the frame they'll come in just under £200 in materiels, so the cheapies really are cheap!
They're pretty robust yes, and there are a *lot* of rivets in there! I'd say the upside is you can build *exactly* what you want and you don't have the problem of trying to fit a "universal" mounting kit if your bike is not common (for universal fitting kit, read "fits nothing properly")
The downside is they are relatively time consuming and labour intensive to build. I've just robbed the design straight from the guy whose blog I linked earlier, just made them narrower. I'll *try* to find time to write up the build once they're done, but unfort I don't think you'll see them at this years rally as there is so much else on this week  :-\