Horizons Unlimited - The HUBB

Horizons Unlimited - The HUBB (http://www.horizonsunlimited.com/hubb/)
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-   -   Self made aluminum panniers & top case (http://www.horizonsunlimited.com/hubb/equipping-bike-whats-best-gear/self-made-aluminum-panniers-top-39773)

yellowbirdrs 31 Dec 2008 04:48

Self made aluminum panniers & top case
 
Today morning I start bending and cutting the 14 ga (2.1mm) aluminum sheet. Tomorrow I will weld the boxes and finish them.
http://img123.imageshack.us/img123/3...ge00200xq0.jpg
http://img239.imageshack.us/img239/9...ge00196jt1.jpg
http://img238.imageshack.us/img238/6...ge00197ye6.jpg
http://img49.imageshack.us/img49/9580/image00198ji4.jpg
http://img255.imageshack.us/img255/4...ge00203sl8.jpg
http://img239.imageshack.us/img239/7...ge00210st3.jpg
http://img123.imageshack.us/img123/5...ge00209cf8.jpg
http://img187.imageshack.us/img187/1...ge00211ro7.jpg
http://img238.imageshack.us/img238/9...ge00208kp8.jpg
http://img267.imageshack.us/img267/6...ge00207fn7.jpg
http://img123.imageshack.us/img123/5...ge00213gt1.jpg
http://img238.imageshack.us/img238/5...ge00212tv9.jpg

yellowbirdrs 1 Jan 2009 04:21

Yesterday size test & preview on the Vee:
http://img71.imageshack.us/img71/8897/00004ti2.jpg
http://img126.imageshack.us/img126/4982/00003to0.jpg
http://img234.imageshack.us/img234/6092/00002zk5.jpg
Today welding and finish the panniers just left the top case and the rack for the weekend.
welding details:
http://img357.imageshack.us/img357/9578/00016en3.jpg
http://img387.imageshack.us/img387/2760/00015kb0.jpg
http://img387.imageshack.us/img387/6987/00011oa2.jpg
http://img71.imageshack.us/img71/5808/00010hy7.jpg
http://img71.imageshack.us/img71/8448/00017ye3.jpg
Inside view:
http://img387.imageshack.us/img387/4331/00007wl9.jpg
Finish case: :oops2:
http://img68.imageshack.us/img68/6781/00006ns7.jpg
http://img234.imageshack.us/img234/1296/00006rg1.jpg
http://img78.imageshack.us/img78/3836/00013gm0.jpg
[FONThe welder machine Miller Syncrowave 350 LX
http://img234.imageshack.us/img234/3632/00012rk6.jpg
Note I make a little mistake I welded the bottom pan in the top of the box #2 and that ruined my design :rolleyes: the tow 90 angles should have been in the rear inner side. :(
The blueprints:
http://img78.imageshack.us/img78/5363/image2if8.jpg
http://img71.imageshack.us/img71/387/imagebx2.jpg

Happy New year!!!!

steveindenmark 1 Jan 2009 16:08

This is an interesting job.

Keep posting the pics as you go along. I am looking forward to seeing the finished project.

Happy New Year.

Steve

Big Yellow Tractor 1 Jan 2009 16:10

An easy mistake to make :-(

You might as well make another two so you'll have a set to sell.

yellowbirdrs 1 Jan 2009 22:51

Quote:

Originally Posted by steveindenmark (Post 220816)
This is an interesting job.

Keep posting the pics as you go along. I am looking forward to seeing the finished project.

Happy New Year.

Steve

I will, just need to finish the top case and decide in which color I will adonize the boxes or maybe just the box covers. :unsure:

Quote:

Originally Posted by Big Yellow Tractor (Post 220817)
An easy mistake to make :-(

You might as well make another two so you'll have a set to sell.

Yes I will make some other sets for sale under request and for fixing this little mistake I probably juts weld the other sides the same way and cut the top panel 15-20mm inside to get a a inner lip.
somthin like this:

http://img99.imageshack.us/img99/3295/imgp2446jp5.jpg
http://i1.ebayimg.com/02/i/001/26/e3/7736_1.JPG


?c?

Ironheadziggy76 7 Jan 2009 23:36

How are the cans coming? I am VERY interested in the top case, I will be making one myself soon! Get busy! :thumbup1: I would love to access to those tools.

Hooli 10 Jan 2009 16:50

have we got an emote for 'i hate you because you have way too many cool machines to play on'? :rofl:

Linzi 10 Jan 2009 19:42

Garden Sheds
 
Man that's some shed you've got mate! All I've got is a bike cover and a socket set! I was proud of my new torque wrench till now. I'll keep quiet about it now though! Linzi.

yellowbirdrs 26 Jan 2009 21:53

Thanks for all comments, feedbacks and advises.
I finished the panniers and the top cases last week and decide to did a fast 1K road test on MX. Hwy 200 coast road ;) . The panniers are sarongs, quite and waterproof.
I also did a extreme close sand inspection and the pannier (right side) didn't bent or broke :thumbsu:

here some photos:
http://img145.imageshack.us/img145/8960/dsc09589tq6.jpg
http://img84.imageshack.us/img84/9139/dsc09919nw2.jpg
http://img145.imageshack.us/img145/3699/dsc09794zt0.jpg
http://img84.imageshack.us/img84/540/dsc09609kv0.jpg
http://img134.imageshack.us/img134/3470/dsc09613tr2.jpg
http://img98.imageshack.us/img98/7199/dsc09596yb1.jpg

Rebaseonu 27 Jan 2009 01:38

Wow, that is a lot of storage. How much is total volume in liters? :rolleyes2:

How about replacing big top box with a roll bag for lower center of gravity? I guess handling of the bike will be much better. I'm sure you'll make next ones smaller. ;)

steamerstimpson 27 Jan 2009 05:44

These are really nice boxes.

I would like to look at the attachments that you are using. do you have pictures? are they slung or bolted on or both?

I would like to get something like this made in a developing country, rather than dragging them along with me on the plane. In the absence of 2.1mm ali and facilities to weld it, what thickness of steel would give the same strength? I guess at least 1-1.5mm. I would reduce the depth to keep the weight down, of course, they would need to be painted inside and out too if using steel. Another option would be to use thinner gauge ali and rivets and possibly ribs for strength.

yellowbirdrs 27 Jan 2009 19:48

Quote:

Originally Posted by Rebaseonu (Post 225535)
Wow, that is a lot of storage. How much is total volume in liters? :rolleyes2:

How about replacing big top box with a roll bag for lower center of gravity? I guess handling of the bike will be much better. I'm sure you'll make next ones smaller. ;)

The panniers are 45L each and the top case is a little biger I guess 45-50L

Quote:

Originally Posted by steamerstimpson (Post 225543)
These are really nice boxes.

I would like to look at the attachments that you are using. do you have pictures? are they slung or bolted on or both?

I would like to get something like this made in a developing country, rather than dragging them along with me on the plane. In the absence of 2.1mm ali and facilities to weld it, what thickness of steel would give the same strength? I guess at least 1-1.5mm. I would reduce the depth to keep the weight down, of course, they would need to be painted inside and out too if using steel. Another option would be to use thinner gauge ali and rivets and possibly ribs for strength.

I made the mount system to be 2 parts 1 bolted on the panniers and one to the bike the panniers is like an omega and slice into a 2 rails on the bike part so you can remove the side cases fast and easy. I will post some photos latter.

About the steel boxes I'm not sure because of the weight and rust issues but if you need a cheap and a 1 time boxes I'm sure it is the way to go on a trancontinental trips.

_CY_ 3 Jan 2012 01:09

nice job on the boxes... now that's a large top box!


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