Ammo Cans......on a Diet - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 19 Old 08-31-2010, 11:27 PM Thread Starter
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Ammo Cans......on a Diet

Pictures below show my newly finished Ammo Can Panniers mounted on Happy Trails Rear Racks. I placed each 22 lb can on a small weight-loss program and was able to drop approximately 5 lbs off each by cutting out the heavy sheet metal and replacing with aluminum panels. Stainless steel buttonhead allen bolts + nuts hold the panels on....along with caulk/sealant between the two metals. The original ammo cans are super strong.....they are built to hold/carry bullets aren't they?? I made "Z" shaped brackets out of aluminum which supports the cans on the Happy Trails rectangular tubes. Also used (but not shown in the photos) are a pair of "U-bolts" on each can to make sure they don't come off the racks (and act as thief-deterants). Painted a semi-gloss black using BBQ Grill paint, they aren't really fancy........and I like em that way. I haven't decided yet to make one end of the lid "hinged" .....or have a lockable eye-bolt on each end (which might be a PITA if getting into the cans more than once or twice a day?). The aluminum bungie grab bars on top are kitchen cabinet handles from Lowe's.......at $0.97 each. I mounted a helmet lock (donated from a zrx1100) on the left box.......and a bottle opener on the right box!! I can remove the boxes from the racks in about 4 minutes. Can't wait to try em out on an over-nighter this Fall.

Happy Trails Racks.....and my 4"PVC Tool Tube.



The "Z-shaped" brackets.......

The zrx helmet lock......

....and the bottle opener (the box shown on the left).




:mrgreen:

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post #2 of 19 Old 09-01-2010, 12:58 AM
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Nice work there, Mark. Looks like they'll still maintain their robustness. What gauge aluminum did you use?

'09 VStrom DL650A - Sold.
'04 Suzuki Burgman 400 - The wifes
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post #3 of 19 Old 09-01-2010, 07:20 AM Thread Starter
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Originally Posted by LowAndSilent View Post
What gauge aluminum did you use?
About 3/32" thick.......I have a sheet of it in the ManCave......use it for all kinds of DIY stuff (the muffler heat shield is made of it.......Happy Trails racks require you to remove, or modify, the stock shield).

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post #4 of 19 Old 09-01-2010, 08:27 AM
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mmm...Interesting.

I just wish someone would make an aluminum set that looked just like the ammo cans! :mrgreen:

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post #5 of 19 Old 09-22-2010, 09:45 AM
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I just mounted Mermites and wish I had seen this post beforehand.

Did you make the Z Brackets out of Aluminum? How thick?
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post #6 of 19 Old 09-22-2010, 10:35 AM
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i have these EXACT cans and i can tell you, it is a pita to get into them with 2 ubolts with locks. i have plans to shave a side of mine and hinge them this winter.
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post #7 of 19 Old 09-22-2010, 04:10 PM
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This setup looks great I wish I had some skills. I would make a set myself. They are cheap, look good, hold a bunch of stuff, and a bit lighter than the originals.

Curious. How much do the aluminum models weigh?

2012 DL650 Adventure
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post #8 of 19 Old 09-22-2010, 05:17 PM
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Quote:
Originally Posted by bikefree View Post
This setup looks great I wish I had some skills. I would make a set myself. They are cheap, look good, hold a bunch of stuff, and a bit lighter than the originals.

Curious. How much do the aluminum models weigh?
The Mermites?

Around 10 lbs I would suspect.

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post #9 of 19 Old 09-22-2010, 05:42 PM Thread Starter
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Quote:
Originally Posted by C-Stain View Post
Did you make the Z Brackets out of Aluminum? How thick?
Yes......al-you-mini-um.....alittle less than 1/8" thick, I believe.......I bought a sheet of the stuff last year and use it for various projects. Need a band saw ($100 at Lowes) to play with it.......:mrgreen:

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post #10 of 19 Old 09-22-2010, 09:33 PM
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Nice touch; you now have a CUSTOM Strom.
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