Best design for aluminium boxes?
 

It seems that bike luggage box design has reached its limits. The Jesse design, (reflected in the new UK outfit Projectvnd) seems the best. The boxes have beveled edges for lean-angle and for paddling. They are custom made to fit best to maximise space and minimise width. They are 2mm. The racks work, and are strong. All good, and miles ahead of the overpriced TTech. So is there anything more that can done?

I ask cos I am in the process of building some for myself.

When it comes to Jesse I will not say the rack is strong, I have welded mine several times (10-15) and it’s now rebuild so it works (it didn’t even fit my bike). I have had no luck in ordering parts for the system, in fact I’ve had no luck getting in touch with Jesse at all the last years.

The locks broke and the mechanism for locking the boxes to the frame also broke, the new system looks even weaker, but other then that the boxes are nice….

That is a shame, because the design of the boxes looks very good.

I met an overlander recently who has gone halfway around the world with Jesse luggage.
He complained of the new combined handle-lock system. "Too flimsey" he said. He has added proper locks.

What part of the rack broke? Where is the point of weakness?

Check this:

http://www.horizonsunlimited.com/ubb...ML/000189.html

Simon, What kind of bike are you putting the boxes on? I built my own for a bmw r80rt and they (luckily) turned out well. Email if you would like some info. Cheers, Peter

I am riding a Transalp.

I am just completing a set of boxes for it. Having looked long and hard at all the boxes on offer, I am absolutely certain I can do better. Each one has a weakness or two.

It is worth baring in mind that many manufacturers, despite what their publicity says, are building for the gentle European touring market. Not overlanders. That is why the Touratech ones are so shockingly poor for the money.

The ultimate overlander boxes are only days away...

im not impressed with the ali boxes that come with the 1150GS adventure(and cost so much!!) they seem not very well made and too small.i dont think you will get a full-face helmet in any of them. the new 1200GS has expandable plastic boxes as accessories, ive not had a close look at them but its a good idea and looks quite neat. has anyone had a close look? maybe an idea for any of you DIY fans?

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dave

I have used Jesse's for years, have crashed badly on them and no damage-infact they act as a crashbar due to their design strength. In China last year in an accident, one was crushed and subsequently repaired and it never leaked. Never damage to the frame system, and never has the frame failed. If you want to spend a dime call them:623-878-7113 USA, and get the parts needed to replace anything they make. They are a busy company but do respond.I don't know how their overseas distributors operate however.
Allen.

I can recommend Happy Trails rack and pannier setup. I don't know how they compare with Jesses, but they are certainly stronger than Touratechs (I've had both). They're at www.happy-trail.com. The customer service is also outstanding, in my experience.

Mike
Idaho

The new R1200 GS panniers?! Mmmmm. I see them for show and not much else. Sure they are nice and square now with neat little bags. But the mechanism for them to widen is a gimmick. The mechanism itself takes up valuable space and I'm always dubious about moving bits, which wear and can break. Stick to the ali panniers, whatever the make.

[This message has been edited by Dream Catcher (edited 18 May 2004).]

OOoops. One other thing on aluminium panniers. New outfit in the UK called Metal Mule. www.metalmule.com. Riveted boxes with "QuickAttach" system.

I had the Touratech boxes and pannier frames made by Erni at Overland Solutions. The bike fell over a number of times and even with all the weight of the bike and our luggage there was no damage to the boxes or the frames. Because the Boxes were fitted slghtly lower than with the original frames there was no damage to the bike either.

Remember not to make your pannier support frames too strong... or "when" you fall over the bike frame may break and your luggage will be intact.
I used the original bmw pannier frames on my R80RT, which are silver soldered (not welded) they withstand vibration better and will bend or break BEFORE the bike frame does.

They have survived two stationary fall overs and two low speed crashes...so far

The boxes are basically like jesse's but with flat, unhinged removable tops.
Cheers

I use to think the same until I saw this
http://patineto.smugmug.com/gallery/108392
Roger the guy that makes them is not only a pretty good designer but a extremlly skillfull fabricator

take a look at this link on ADVrider to learn a little more about them
http://www.advrider.com/forums/showt...highlight=mamf

he custom makes them for anybike,all hand made

i hope this helps

I can thoroughly recommend Metal Mule panniers. They are a result of many years of travelling revealing the good and bad points of luggage and designed to be as tough as old boots. Fast attach system, optional extras to suit individual needs and being waterproof are just a few bonuses with this set up. Have a look at www.metalmule.com
Jim

I know a lot people like Jesse's and I have nothing else to compare them to but after my a long weekend trip testing my installation I think there could definately be improvements.

The locks are worthless. Any kid with a large screwdriver should be able to pop them open. There are latched for using an external padlock but the are secured by two philps screws. I didn't use an external lock but the latch fell off somewhere between NYC and Canada. This is a heavy piece and I hate to think that this flew into a car. Several bolts came loose, but I do no attribute this to a design flaw. I didn't use locktite because I wanted a test run first.

They get very hot. Again, this is probably true for all bags, but I have a suggestion. Add vent holes and an optional fabric cover like the rain covers for tank bags. Preferable a light color, either white or bright yellow. Perhaps this could be lockable as well. How about some rubber washers or something to help reduce vibration.

There are no means to attach items to the exterior of the bags.

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Brooklyn Dakar
http://motorcycleramblings.blogspot.com/

I really like the look of those custom ones by Roger from Germany, especially the minimal rack, but the weakness I see here is that they might be difficult to take on and off. I notice for stability that the box attatches to the pillion footrest, and there is a bar between the two boxes at the back, so the boxes are themselves perform part of the role of a more traditional rack.

How often do people like to remove their boxes? I have touratech 41litres on an F650 dakar, and needed to take them off sometimes just becuase of the width, other times it was useful to be easily able to remove them for other reasons. This is a good aspect of their rack and mounting, but where I think it really falls down is the amount of stress around the mounting with fully loaded cases - after a year on the road my cases have cracked around the plastic mounts - due I think to a combination of weight and vibration

Richard

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Richb
http://www.postmaster.co.uk/~richardbeaumont/60684/

Hi

Ahhh... doncha just love ally pannier debates.

FWIW I've been very happy with the Touratech frames and boxes on my R80 GS. Survived Indian full-contact traffic and a 40mph crash with minimal damage. Nice and light, easily beaten straight. I'd use 'em again, no question.

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Sean

Hello. I recently built a set of boxes for my GS and would like to comment on removal options. I chose to make mine solid mount with the bar across the back, similar to the ones featured earlier on the KTM LC8. The bags contain my tent, sleeping bag, cold weather gear, cooking equipment and food. These are items i prefer not to carry into the hotel when i choose to stay at one, and i usually park my bike where it is secure. Fully loaded i can still pick up the bike after a dump http://www.horizonsunlimited.com/ubb/frown.gif and if i really want to do some hard off-roading, there off tn 5 min. With four allen-head bolts each. Most important is the strength added to the frame with solid mounting. Been on the road for a month now, both on and off road, and this has worked out very well for me. Just my 2 cents...

Here's what I had built by Overland Solutions in the UK.

http://www.nohorizons.net/framed.htm