Project pannier build.

[rusty]

Good man kenny87, looks good and secure.

Managed to steal a hour for the man cave today. I got pannier #2 done



I think my twin is pleased with the progress. :laugh: :laugh:

[rusty]

Have you heard of macrolon? I was recommended it but never used it myself. It can be heated. And bent into mounting hooks but locking still a challenge.

Thanks Kazakdan, I'll look into that.

Cheers
Gerry

[Kazakdan]

It might be spelt makrolon...

[rusty]

Ok folks, a quick update.

Made an attempt at one base. Now I knew in choosing the double 45 degree's, the bases and lids were going to be present some problems. It took me a while to figure the cuts and with the help of my daughter and her tec graph skills we got it sorted.



It is not a tight fit as the bends are more curved rather than a perfect 90.





I'll post photo of the cuts in the next post.



Doesn't look too bad from this side.







I suppose I could use plenty of silicone to seal the gaps and I intend to line the boxes with a thin layer of foam or the like, so it won't be noticed.


That it for now.

Cheers.

[kenny87]

You need something heavy, square and hard. A piece of wood would do at a push but metal would obviously be better. Holding it against the inside of the bends, gently tap the outside with a hammer and you'll soon tighten everything up. I've seen worse with 50 grands worth of bending machine so seriously well done!

[kenny87]

Also, ratchet strap around the bottom of the pannier will pull everything in while you get everything fixed in place

You have a pm btw

[rusty]

Also, ratchet strap around the bottom of the pannier will pull everything in while you get everything fixed in place

You have a pm btw

And one sent back. Cheers

[rusty]

Well got another bit done today. Made the base for pannier #2
Here's a few pics of the cuts and bends required as promised.







I am waiting untill I have everything together before I assemble them.
Seals for lids on the way from here, http://www.sealsdirect.co.uk/listDepart ... teAreaId=1

Latches/locking systems from here, http://www.protex.com/product/index/cat ... +Fasteners


I also had a go at the top box, I tried this in one complete sheet.










I'm sorry now that I didn't do the panniers like this. It would mean less rivets, sealant and less chance of leakage..
Ah well you live and learn.

Cheers
Gerry

[rusty]

Well, I've been working away at my boxes over the last couple of weeks, when I could steal a hour or two. Been busy with a 21st (not mine unfortunately) and getting the house ready and all that.

Anyway, I'am nearly there. Boxes are assembled and lids are made. I just need to get the seams on the corners welded.












Really happy the way this worked out. :thumb:

[I of the strom]

Looking Great. You should be very pleased with your work. As you have saved a bundle on these and celebratory drinky is well in order :cheer: