After making soft luggage racks, I thought I might give aluminium panniers a crack. I've never welded ali before, it's a right sod....and I'd need an inverter (TIG AC/DC) welder which by comparison to other welding units are pricey to say the least. Anyway....
First gotta cut the ali sheet with the plasma cutter:
then bend the plate on the sheet metal bender Iknocked up for the job
then weld the seam...taa daa...almost there after burning many holes
Dimensions will be 16 inch deep. Length 45cm width 30 cm. Each plate bend begins with 45cm, then 30, then 45, then 30 (which makes the box sides) then a final bend which is cut short at about 1 cm for the lip.
Bottom is made 46.5 x 31.5 cm with a deep scoring from a angle grinder on the 44.7 x 29.7 lines. These are then bent up and form the lip for the weld. Lid is made the same way, only scoring is made on the 45.3 and 30.3 lines. Lid hinge is made from a Tpiece rod. The lid has to raise vertically an inch before the rod clears the brackets and can roll back on the Tpiece. Panniers mount to the frame via a locking sissor piece that clamps the two mounting bolts and rests on a pannier frame lip.