There is a useful link here, it is in Italian but it contains pictures:

Borse in alluminio per moto autocostruite (Sahara.it)

use your keyboard's arrow keys to scroll the page if u are using Mozilla Firefox, the site is an Italian "mini" HU.

I am building my own panniers on the same style plus rack for my XTZ660 3YF, will post some pics soon along with instructions, I am using 2mm thick allu sheets and 3x3cm "Ls", no welding, the major problem at the moment is how to make them 100% waterproof.
Will keep posting.

Regards to all.

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... and Nelly The Elephant packed the trunk and said goodbye to the circus...

Use 'Sikaflex', it's what they use in the auto industry, this stuff sticks better than nuts and bolts, and is 200% waterproof
Try here TSW-Comsat


Trophymick

Alex,
I was going to suggest a thin layer of rubber/neoprene/whatever between both sheets, along the length of the joint, prior to riviting them.
But I since read Trophymick's post and like the idea of an applied adhesive/sealant as well - if it has some flexibility.

The problem with both methods is what happens if there are extreme forces applied - like falling, an accident or using the box as a support for other activities such as wheel removal.

Please report your progress. I am most interested at I am close to buying a set of Metal Mules which look, feel and are reported as superb, but they do cost a lot compared with the raw materials. Maybe there is no shortcut to knowhow, but it seems sence to explore alternatives..

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Vitim Bridge Clubwww.advrider.com/forums/showthread.php?t=533442
www.sibirskyextreme.com

I think i will use rivets and "low module" sealant the same used in the glass facade industry (also used in the light carpentry, air conditioning and car conditioning/caravan industry).
I think spreading a thin layer of this sealant in between the "Ls" and allu sheets before riveting and then fill the gaps and the rivets ends to seal the inside of the boxes before glueing the padding inside (for this my choice fell on regular cheap camping/exercise mats) would do the job.
The only real problem are the corners, especially when the lid meets the rest of the case, a very easy solution is to make a sealed lid bigger than the body then fit a rubber seal to the upper edges of the case, a cars door protector is flexible enough and durable, so the water won't be able to "go up" and flood the panniers.

On the internet I saw some really beautiful cases but I never thought i was going to get those expensive "solution" from touratech , i used to make alluminium cases for myself a few years back (I have been a DJ with a very low budget start then for friends etc. - see some example below) and i know it is a job anybody can do with a low level of DIY experience.
I am willing to help anybody wanting to make their own cases as it is a very easy job and it can be done with a basic set of tools: drill, hammer, rivets, saw, screwdriver... that's it...
for the rack u may need some welding skills but not necessarily.






I estimate 100 euro as the total cost but I am still working on them and will post some pics and more details in a few days.

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... and Nelly The Elephant packed the trunk and said goodbye to the circus...

Trophymick,
my mistake in the description:
I will use a Butyl Rubber based sealant on the outside in between the bits before riveting and the low module silicone will fill the remaining gaps inside.

Tmotten,
I like the electrical plug, its a good idea. Just one thing: you cant remove the topbox from the bike?
Just an idea thrown in: there are sone take-apart (or slip-apart) hinges on the market they work as the normal ones with the added advantage that they can be taken apart letting you taking the lid completely off the case (the box from the rack in your case). If fitted instead of the normal ones u could still swing the topbox to access the saddle latch but also you could take the box off in a second.
Some pics below:

Take-apart hinges:




or Slip-apart hinges:

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... and Nelly The Elephant packed the trunk and said goodbye to the circus...

Not to worry. It's only for big overland trips. In Aussie on weekends or longer I ride like this. No camping though but I'd probably go for a strap on tent and sleeping bag arrangement.



I'm not too worried about the size if the weight is kept down. Last time we rode accross northern Asia on a Tenere that Dave Lambeth setup with 2 x 6 litre Acerbis tanks on the back. He really liked the setup so we thought we'd go with it. It was pretty successfull, but that weight would be more than we will be putting in those boxes. That's why I like building boxes around the luggage rather than the other way around. On trips like that it's all about the getting there eventually in any way shape or form, so you tend to take it easy.

I would have to remove the 6 nylock nuts, but that is the idea as I would only use this on long trips I reckon.

I have had a quick look at those hinges, but wouldn't I need to build a brace or something to stop them sliding off?

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Tacos Tyring Travels.com

Only the Slip-apart ones may need something that stops them from sliding off sideways but i noticed your mechanism to secure the topbox to the rack, that woudl be enough.

The Take-apart ones dont slide sideways, in order to take the lid off u need to open it at least 90degrees.
Here is a better picture:

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... and Nelly The Elephant packed the trunk and said goodbye to the circus...

Get Alpos boxes - half the usual price.

Very nice boxes indeed especially the F Series but do they make something the size we need? 782x585x412 mm seem too wide IMO.

link here by the way: Alpos - F Series

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... and Nelly The Elephant packed the trunk and said goodbye to the circus...

What about paper machè. Its ever so cheap and easy to do. Perhaps I'll make some this week-end, and post some pictures.

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I remember "Blue Peter" kids tv show , they could make anything with sticky backed plastic , toilet rolls and paper mache .
"This week children we will make a nuclear reactor" , "take an empty washing up detergent bottle and cut it in half - now take the bigger half and place the ---------get down Shep ! bad dog !

Panniers should be easy .[don't ride in the rain ]

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Blessed are the cracked, for they let in the light. - Spike Milligan
"When you come to a fork in the road ,take it ! When you come to a spoon in the road ,take that also ."

You all getting to tied up in aluminum this and steel that.
What you need is some old plastic wine barrels. We cart wheeled our bikes and bashed the luggage over rocks, dogs and bounced off cars.
The lids always went back on and the boxes never cracked.
Get on the plastic freedom barrel bus baby.
Just ride you techno heads.
We went around the world on XT250s with wine barrel luggage.
Lo tech-Lo worry-Lo maintenace.
Just ride you techno heads.
Oh yeh! and it only cost about AUD$85.00 for both bikes. BANG!!! gotta like that.

Attached Thumbnails

 

 

Wow! How big was each barrel? It looks pretty wide too, but I do like the idea.
Do you have any more pictures, especially side on?

Regard

Nigel in NZ

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The mouth of a perfectly contented man is filled with . -- 2200 BC Egyptian inscription

I have made these..
check out this link from the XRV site..
Home made panniers... - Honda Trail Bike Forums

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2000 Africa Twin
http://two-up-ona-twin.blogspot.com

Almost there....!!!!

Still a bit dirty from the sealant that needs to be trimmed once hard, the lid is missing from the pics and the inner padding needs to be glued but i am slowly getting there..!!
I thought I posted some pics because I am excited they are coming out the way I wanted (water-proofing test by immersion in my tub is scheduled for tomorrow...)

Will post some instructions and the list of the materials i have used. It's quite chaep and easy to produce spending just a couple of hours after dinner for a few days.

How to spend my weekend nights... "sadly" somebody commented... any satisfaction from the hubb community..?

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... and Nelly The Elephant packed the trunk and said goodbye to the circus...