patracy
08-20-2006, 01:51 PM
Continuing in the tradition of a fully functional farkled out frugal strom. I present the latest creation from the lab of Dr. Frankenstrom. My removable, expendable, frugal pannier system.
Before you scoff at the pics, how many of you have a full luggage system that costs less than $70 total, and can be repaired for about $14 a side if damaged?
Anyhoo...
I used a set of ammo boxes from a army surplus store. Some 1/8" thick by 1" flat steel, some 3/4" alum angle (back lower cross brace), 4 12mm bolts, 8 12mm flat washers, 4 12mm split washers, 4 12mm wing nuts, 2 10mm bolts, 2 10mm nuts, 4 10mm flat washers, 2 10mm split washers, 2 10mm wing nuts, 2 8mm bolts, 4 8mm flat washers, 2 8mm split washers, 2 8mm wing nuts, silicone, and some spray on truck bedliner.
First of all I laid out a flat stock across the rear rack mount. I measured the drop I wanted and bent those shapes. I used the from rack mounts for the front. That required trimming the lower portion of the Strom rack due to the angle, but it's unnoticeable once installed. I cut out two sections, drilled the holes for the frame mounts, then installed them on the bike. I used a large crescent wrench to work as a metal brake. I used the passenger rearsets as another attachment point. Basically Just drilled holes in bar stock cut to length and tweaked as needed.
Here's a view of the bike without any luggage on it.
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00430.jpg
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00431.jpg
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00432.jpg
I used the 12mm hardware on the two upper mounting tabs. Basically I ran a bolt through the ammo box with washers on both sides, and a nut on the outside. Slip them into the hole and throw a lock washer and wingnut on the outside. I wanted something I could take on and off without tools.
While installing the hardware, to prevent water entry, I used copious amounts of silicone on the bolts.
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00433.jpg
I used the 10mm hardware at the front lower section of the ammo boxes in the same fashion as the 12mm's. I used the 8mm's as well in the rear. Along with the alum angle stock. I used alum to save weight since the rear isn't handling the load, just stopping any swaying motions. I had to trim up my rear fender a tad to make it clear. Nothing a grinder couldn't handle.
Here's a view of one of the cases with my toolbag, first aid kit, and cable and lock. Still have plenty more room left.
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00434.jpg
Here's the completed shots
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00435.jpg
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00436.jpg
Other useful things I've found are that the cases make great stools for working on the bike.
I'm also going to fab up a system for a top case as well. I'm looking for some sort of black alum toolchest or something along those lines. I'll also build a quick release system for it as well.
Before you scoff at the pics, how many of you have a full luggage system that costs less than $70 total, and can be repaired for about $14 a side if damaged?
Anyhoo...
I used a set of ammo boxes from a army surplus store. Some 1/8" thick by 1" flat steel, some 3/4" alum angle (back lower cross brace), 4 12mm bolts, 8 12mm flat washers, 4 12mm split washers, 4 12mm wing nuts, 2 10mm bolts, 2 10mm nuts, 4 10mm flat washers, 2 10mm split washers, 2 10mm wing nuts, 2 8mm bolts, 4 8mm flat washers, 2 8mm split washers, 2 8mm wing nuts, silicone, and some spray on truck bedliner.
First of all I laid out a flat stock across the rear rack mount. I measured the drop I wanted and bent those shapes. I used the from rack mounts for the front. That required trimming the lower portion of the Strom rack due to the angle, but it's unnoticeable once installed. I cut out two sections, drilled the holes for the frame mounts, then installed them on the bike. I used a large crescent wrench to work as a metal brake. I used the passenger rearsets as another attachment point. Basically Just drilled holes in bar stock cut to length and tweaked as needed.
Here's a view of the bike without any luggage on it.
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00430.jpg
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00431.jpg
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00432.jpg
I used the 12mm hardware on the two upper mounting tabs. Basically I ran a bolt through the ammo box with washers on both sides, and a nut on the outside. Slip them into the hole and throw a lock washer and wingnut on the outside. I wanted something I could take on and off without tools.
While installing the hardware, to prevent water entry, I used copious amounts of silicone on the bolts.
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00433.jpg
I used the 10mm hardware at the front lower section of the ammo boxes in the same fashion as the 12mm's. I used the 8mm's as well in the rear. Along with the alum angle stock. I used alum to save weight since the rear isn't handling the load, just stopping any swaying motions. I had to trim up my rear fender a tad to make it clear. Nothing a grinder couldn't handle.
Here's a view of one of the cases with my toolbag, first aid kit, and cable and lock. Still have plenty more room left.
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00434.jpg
Here's the completed shots
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00435.jpg
http://img.photobucket.com/albums/v28/patracy/panniers/DSC00436.jpg
Other useful things I've found are that the cases make great stools for working on the bike.
I'm also going to fab up a system for a top case as well. I'm looking for some sort of black alum toolchest or something along those lines. I'll also build a quick release system for it as well.