KLR 650 DIY Fibreglass Pannier Boxes and Frames
 

I fabricated a pair of fibreglass boxes here in Australia for the KLR back in April 2008, shipped them to the US and rode 5,000 highway miles on my US KLR 650 over June and July of the same year. Look to the post below for details.

http://www.horizonsunlimited.com/hub...panniers-35592

The frames are asymmetrical, in terms their offset to the centre of the bike, (right hand frame has muffler offset) and the mounting holes patterns are different too.

The other thing I consider essential is the stiffening between the main frame and the rear sub frame, by adding a gusset between the peg mount plate and the chassis tube. The factory method of squashing the tube of the rear sub frame and bolting it through to a "U' bracket lets the rear sub frame and panniers develop a real noticeable side to side wobble up at about 75mph or so. The "Billy's Barn" fix my good friend Chris and I did in Pennsylvania is in the pics attached. We used a 40mm x 6mm piece of plate, bent it to access the brake resevoir and battery case, and arc welded it in place. Disconnect the battery before welding, or your arc surges might blow a diode in the alternator! Fixed the wobbles, no problems! Good Luck!