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Contact Overland Solutions for all your custom modifications and setup for overland travel.

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  #1  
Old 15 Dec 2008
indu's Avatar
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DIY alu panniers

Sorry if this has been posted before, but it is such a GREAT how-to on making your own watertight alu panniers and rack that I couldn't risk it to not being available to you guys.

Here it is. I'm tempted myself...

rtw.xtz660 - Home made aluminium boxes
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Old 16 Dec 2008
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I made 2 pairs similar to these,1 for my LMF and the other for my partner's Pegaso,mounted them on my own frames.A good source of the ballcorners and ally angle is DJ Equipment, Decks, Mixers, Pioneer DJ, Buy DJ Equipment from Djkit.co.uk although the over-centre catches they supply are not stainless so will tarnish over time...an occasional spray with something like WD40 helps here.A couple of extra tips on going down this route though;
- make sure you use closed-end pop rivets or water will seap through them
- instead of using normal silicone sealant or tigerseal,i used grey lead flashing sealant from a builder's merchants.It does'nt contain acidic substances which will corrode the aluminium and is almost the same colour as the ally itself.
- take your time making them...it 'aint a half day job!
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Old 1 Feb 2009
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Thumbs up DYI Panniers

Here's my GS with the 50ltr Panniers I made. I work on Sea Planes so I made mine like I build Floats, water proof sealant and Bucked solid rivets, I too have over-center latches with key-a-like pad locks and aluminum drawer handles. I also made my lids into tables with folding legs.
Thanks to the guy that posted his DYI Pics from "rtw.xtz660"

Later

P.S Check here for more pics..
http:// myspace.com/scottmglover
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Last edited by S Glover; 1 Feb 2009 at 04:12. Reason: More Info
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