hi,
i wanted to go to Italy from Norway, and found out that I needed a couple of pannier. After experience that it took two weeks to order and some 800 euro for this boxes I found out I could make them in one week and make them for 80 euro instead.
Here is the description:
1. buy 2 mm aluplates (dont need to be any special stuff. 5052 or similar should be ok.
2-3 m2 should be enough (then you have some spare for other project also)
2. use tig for welding. it makes its easier. 80 amp seems to be enough. (Im not a pro-welder, just an ordinary hobbyfarmer who weld for fun)
make boxes in plywood first to see if it fits you. Mine ended up in size (lxhxd) 48x36x20.
I wanted them in 28 cm first to hold a helmet but found out that they get too big. so 20cm seems to be wide enough. 20cm will also hold a jerry-can. (which can be useful)
3. I make my own fastening on the frame (in steel of course) i found it easier than trying to use some of the fasteing which is already on the bike
4. Then I made a frame in alu to fasten the boxes.
5. after that I welded to boxes. Not the world most pretty ones, but solid enough.
6. I didnt make any topbox since I wanted to have a backback there.
see pictures. (if you have more questions please mail me on jonnyb@opera.com)
(I have a bunch of pictures but this stupid forum only allows 3 pictures) :-)

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some more pictures.
I have only 2 fastening on each side on top and a fasteing between the boxes on the back of the bike. (no-one in the front which seems that all other have). I tried to get the boxes as close to the bike as possible. so there is only a few mm clearance between boxes and exaust pipe on right side. (totally 12 cm arm from bike to boxes) that means I had to move the blink-light further back.

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Excellent job mate !!

Makes me wish I could weld aluminium.

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nice job.you should market them 400 euro.

Looks good. Here's what I whipped up w/ some surplus 'Pelican' cases from eBay.








--JOsh

Cool...I'm willing to try and do one for me but just for a spare helmet

Ride safe!

I tried to make my own panniers! The boxes were OK. 2mm ali with 2mm angle and pop rivits. Had a nice little bend for the exhaust and all. Then it came to the frame. Well it looked like a bird crapped all over the welding , but i think it was strong. Then the fixing to the frame. Thats where i lost my temper and quit! Pissed off i sat in front of the computer and ordered the first panniers i saw on the net! So now my panniers are worth more that my bike!
So, only make panniers if you really have to , or really want to!

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I dont understand this. i spent more time on the boxes than frame. basically you need some place to fasten the frame to the bike (i made my own) and some kind of frame (my is very simple, to small arms around 12 cm (as in picture) and a rectangular frame on back of the box (basically its not necessary) but its good to have to make it stronger.
I did ofcourse do everything in wood first (a fullscale model) to see if it fits. i think most people just start to weld and end up messing up the hole thing. a model makes you more flexible and give time for experimentation. (when welding, you usually only have one chance)

Hi,
Those are some impressive looking panniers! Im sure they will be great for Norway to Italy, but please BE WARNED; that frame will disintegrate on a trans Africa trip- guaranteed! I have snapped 25mm steel angle iron frames twice on very long very rough roads...
Home-made is the only way to go! Just think strong and use as many attachment points as possible- indicator mounts dont count!

Jim

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