Fully Custom Panniers
First time posting, so some background first: I rode motocross for a couple of years before a scare put me off. My dad bought a VStrom in 2009 that I have stolen from him as he's moved to an R1200GS. I'm an engineer that loves tinkering and designing, hence the following questions.
I have a 2004 DL650 with Givi Monokey E21 saddlebags. I don't like the look and the volume is pretty limited, so I was looking at the Tusk Panniers for my DL650 and realized there was no good way of mounting them in a way that was a proper quick-release. It all involved tools from the inside. I started figuring out a quick-release mount for the Tusks when I realized the Tusks were not much more than bent and welded sheet metal. Where I work does nothing BUT metal work, including bent&welded sheet metal, including heavy-duty priming and painting. I started designing some fully-custom metal panniers (including quick release mounts for the Monokey racks) and am just about ready to start cutting and folding...but I had some questions.
I've done searches and haven't found anything, so I'll ask here. Has anybody built their own fully-custom hard panniers? Has anyone come up with a properly clever quick-release method for something like the Tusk panniers? I can't imagine I'm alone.