My idea for a pannier alternative
 

Ok, so I am currently in San Francisco on the look out for some panniers. Unfortunately on Craigslist the pickings are a bit slim so I've decided to try and make my own.

After lots of looking around I've been looking at using a cooler like the one below to attach to my already-mounted pannier racks.

http://3.bp.blogspot.com/-ePfHv_f5Be...s1600/esky.jpg

Obviously the idea of having coolers as panniers sounds hilarious but it seems to me to be quite a good fit for several reasons.

-It is light
-It is quite tough
-You can store quite a lot of stuff in there
-It opens from the top
-It is cheap

However, I am a bit hesitant to dive right in, as I'm not sure how to approach attaching these bad boys to my racks as well as I really am clueless as to how I would go about locking these.

Does anyone have any ideas how to mount these to my bike? And does anyone know how I could lock these so my stuff won't get stolen if I leave my bike?

Or maybe this is a stupid idea, let me know what you think. I might end up trying it anyway and posting up my results.

Just screw them on and use simple pet lock mounts from a hard ware store to lock them. Here are many other ideas: Build your own panniers made easy

I love your idea dude, go for it and make some amazing pictures for us!

An Australian couple showed up at the HU meet in Mexico in 2003 with Coleman coolers for panniers, just as you suggest. They were on KLRs, of course. Good idea, if you ask me.

Or bolting on some metal brackets, loops etc. That you could use with tie down straps, ratchet straps etc.

I don't think ice chests will survive long. That sort of plastic is a bit brittle ... will crack. Sun has a BAD affect on it over time. Not good for rough roads or off road.

Look around for soft bags, maybe big duffel bags? ... adapt them to lay over you racks like a Giant Loop type bag. You can find all kinds of travel duffels at Good Will and other thrift stores cheap. Some are pretty good for bikes. Use
Scotch Guard to water proof them. Zippers will leak on most.
http://patricksphotos.smugmug.com/ph...qZrv3Db-X3.jpg

Or .... look on Craig's List in Motorcycle Parts section:

Saddle bags by River Road -slightly used
Faux Leather bags

Large leather motorcycle saddle bags

Teknic Expandable Motorcycle Luggage Saddlebags
Technic soft bags ... pretty good.

Leather bags make good saddle bags. You may need rain covers or use SnoSeal on them. The ones above are cheap. I'm sure there are more if you are patient and keep looking. Stuff comes and goes quick.

Also check Flea Market forum on ADV Rider. Lots and lots of used gear for sale everyday.

Piano hinge down the back & a pair of hasp & staples with padlocks.

Nut & bolt to pannier with big washers on inside of chilly bins.

Finally spray silver (fake aluminium) & apply Touratech stickers for that real swanky "look at me" expensive touch. :blushing:

Mezo.

I think you'll find
the bags will crack ..
from a fall or
at the mounting bolts..
Not convinced .. buy one and 'test' it .. put it sideways on the ground and let the bike fall on it..

Plastic 'pelican cases' will not crack .. I've 'tested' then in deep sand with a fall at 80km/h (~50mph) .. they survived intact.

They seem to be stout,but being double wall construction I think you will find that without having some sort of cradle mount they will prove too weak to bolt on at any location easily.as a top box more easily but seahorse cases can be gotten cheaply with locks and are easily bolted on or use the happy trails lugs.

Pelican cases are super strong but may be above budget? I've used Pelican since 1985 carrying Audio and Video equipment all over the world. Very tough and a "no question" lifetime guarantee. They are also 100% waterproof. Go ahead, use your Pelican for a Life Preserver ... it works!!

The Airlines broke two of my Pelicans, the company replaced them both INSTANTLY, no hassle at all!. They have been redesigned since then to strengthen the hinge and closure area ... now stronger than ever.

I have never used Pelican's on a bike! :blushing:

Coolers are made with an extra double wall for insulation so there's a lost of space here, decreased density, more volume for nothing to slow down the bike. That is no use for you unless you plan to carry your lunch in there.


There is plenty of boxes out there sold for various uses. I'm sure you can find something a bit tougher with no lost space and for cheap too.