Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Tech

Tech ALL bikes: "Generic" tech questions and answers. Maintenance, general discussions etc.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

LinkBack Thread Tools Display Modes
Old 16 Dec 2008
indu's Avatar
Motorcycle Addict
Veteran HUBBer
Join Date: Aug 2001
Location: Oslo, Norway
Posts: 441
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
Reply With Quote
Old 16 Dec 2008
Contributing Member
Veteran HUBBer
Join Date: Jun 2005
Location: cardigan,wales
Posts: 251
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!
Attached Thumbnails
DIY alu panniers-t1-090.jpg  

Just going for a short ride on my bike....
Reply With Quote
Old 1 Feb 2009
S Glover's Avatar
Registered Users
New on the HUBB
Join Date: Feb 2009
Location: North of Seattle, Wa
Posts: 1
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"


P.S Check here for more pics..
http:// myspace.com/scottmglover
Attached Thumbnails
DIY alu panniers-loaded-for-camping-2-.jpg  

"If you can't Modify, Hack or Repair it, You don't own it"

Last edited by S Glover; 1 Feb 2009 at 05:12. Reason: More Info
Reply With Quote

Currently Active Users Viewing This Thread: 3 (0 Registered Users and/or Members and 3 guests)
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
metal panniers v/s soft panniers zaplaje Equipping the Bike - what's the best gear? 41 9 May 2013 21:10
WW2 era panniers Tim Wood Equipping the Bike - what's the best gear? 0 11 Sep 2006 13:33
panniers for k75 wyomex Equipping the Bike - what's the best gear? 1 29 Sep 2005 14:45
Givi panniers v aluminium panniers simonandmags Equipping the Bike - what's the best gear? 2 13 Mar 2004 02:09


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

Next HU Eventscalendar

See all events


Latvia to Australia, an inspirational 5 month journey full of unexpected adventures!

Renedian Adventures

Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!

What turns you on to motorcycle travel?

Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80 G/S motorcycle.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events (22 this year!); we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, the HUBB or to receive the e-zine. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.

Books & DVDs


All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.

Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!

All times are GMT +1. The time now is 04:17.