any tips for making your own panniers?

[Bolo Grubb]

I have an old Eddie Bauer book bag that I think will make a good pannier.

I am wondering if anyone here has made there own and what tips you may have for a first timer?

I see most pannier have a strip of cloth near the both that a hook goes through, I assume this is to help old the pannier close to the bike. IS this a really necessary piece? I am not sure how to do this on the bag I have. Sewing would be difficult but if that is my only option I can try.

Any tips would be helpful though.

Like what did you use for a stiff backing?

How did you attach the backing to the bag?

Did you use hooks from the hard ware store or buy a kit from Arkel or Oblieb?

How durable was your bag?

any thing I should know that I have not asked?

[StephenH]

See this thread:
http://www.bikeforums.net/showthread.php?t=392675

[n9ots]

Hello:
The instructables plan looks cool.
For the sewing bit I would recomend picking up a speedy stitcher

http://www.speedystitcher.com

I've had one for years and it has to be the easiest way to sew thick materials.
I often sew through two layers of webbing with a plastic stiffener (a.k.a. hacked up "rubbermaid" bin) between, and have no problem doing so.
And the thread it uses is waxed nylon that will hold up better than almost anything else.
They can be found at most older Ace Hardware stores.(among other places)
If you do follow the instructables idea add the interior stiffener or at least an interior webbing patch to reduce the risk of tear-out with heavy loads.

On a side note when my panniers from Preformance self destructed (the corrogated plastic stiffener snaped under heavy load) I replaced it with a sheet of luan (sp?) (plywood like material) and haven't had any problems since.
Have fun
ben

[AllenG]

http://www.bikeforums.net/showthread.php?t=236014
http://homepage.mac.com/awcg/.Pictures/Bike/CP1.jpg

http://homepage.mac.com/awcg/.Pictures/Bike/CP2.jpg

I used Ortlieb small parts. After a couple of years my bags (made 2) have held up very well and still have several years more life.
The bags I used (Osprey Torque series) have simi-rigid sides.

[Bolo Grubb]

http://i190.photobucket.com/albums/z180/Bolo_Grubb/Pannier/CIMG0867.jpg

Here is the bag I made. I should have taken some pictures as I made it, but I was not thinking.

I had an old pair of Jandd Economy Panniers
http://i190.photobucket.com/albums/z180/Bolo_Grubb/nexus%20hub/CIMG0858.jpg

The zipper was bad on one of the Jandd, so I tore it apart and used the hard backing from it and an Arkel hook kit to make an Eddie Bauer pannier

http://i190.photobucket.com/albums/z180/Bolo_Grubb/Pannier/CIMG0866.jpg

More pictures here
home made pannier (http://s190.photobucket.com/albums/z180/Bolo_Grubb/Pannier/?action=view&current=CIMG0866.jpg)

[Jessica]

my homemade panniers are kitty litter buckets, hardware and standard rear rack. Since I buy the kitty litter anyway, and had the rear rack already, cost was about two dollars. Waterproof, slightly increased uglification on my bike (which I think is a good thing) and pretty big. See CobbWorks.com for ideas/sources for parts.

[Buglady]

my homemade panniers are kitty litter buckets, hardware and standard rear rack. Since I buy the kitty litter anyway, and had the rear rack already, cost was about two dollars. Waterproof, slightly increased uglification on my bike (which I think is a good thing) and pretty big. See CobbWorks.com for ideas/sources for parts.

!!!!KITTY LITTER BUCKETS!!!! (pardon my shouting, I'm just really excited over here :P)

I have a STACK of those darn things that I could never bring myself to throw out. How did you attach them to the rack? (I'm thinking I may just drill a few holes and use zipties...)

Thank you!!!!

[Abneycat]

!!!!KITTY LITTER BUCKETS!!!! (pardon my shouting, I'm just really excited over here :P)

I have a STACK of those darn things that I could never bring myself to throw out. How did you attach them to the rack? (I'm thinking I may just drill a few holes and use zipties...)

Thank you!!!!

You can buy mounting hardware from MEC for something like $10, i've confirmed that it will screw into a recycling bin or a small rubbermaid, so I don't see why a kitty litter bucket would be any different!

I have 4 of those clips left over actually, regular size. If you can use them, you can have them :)

[Bolo Grubb]

http://www.crazyguyonabike.com/doc/?o=3Tzut&doc_id=1841&v=15&term=kitty%20litter&context=all
http://www.crazyguyonabike.com/doc/page/pic/?o=3Tzut&pic_id=248992&v=6&size=large

THis is another guy who made some and here is the e-mail I got him to send me on how to make them.

http://home.thegrid.net/~lllove/bikes.htm

Take a look at the attached pictures. The 1" x 1/16" aluminum flat stock is slightly bent to match the curve of the bucket and attached with double stick tape. There is a matching piece on the inside positioned carefully to match up the bolt holes. I found the easiest way was to drill both aluminum pieces before attaching to the bucket, tape on the outside piece, drill the plastic bucket through the existing holes, then tape in the inside piece, lining up the holes. The hooks are standard tie down hooks bolted through the aluminum-tape-plastic-tape-aluminum sandwich with small machine bolts. You may need to pry open the hooks a little bit to fit over your bike's rack. It's easier to do that before you attach them to the bucket. The bolts seal the holes so it's waterproof. Down at the bottom is a small D tie down bolted thorough the side and used with a small bungee cord to attach the bottom to the chain stay to keep the buckets from bouncing sideways. If you wish, reflectors can be added. All the parts were from the local Ace hardware store. I used Tidy Cat brand cat litter buckets which are rectangular and have attached hinged lids but standard square buckets will work too. The construction is pretty simple and straightforward. I found it to be very durable, but if you do manage to wear out the plastic bucket you should be able to just transfer most of the hardware over to a new bucket. As you have cats, you will have a endless supply of those. There is a company that makes bucket panniers ( http://www.cobbworks.com/ ). Their panniers had a starting price of $80 a pair and making your own costs maybe $10 to $15 a pair.

http://i190.photobucket.com/albums/z180/Bolo_Grubb/Pannier/07.jpg

http://i190.photobucket.com/albums/z180/Bolo_Grubb/Pannier/06.jpg

I think I am going to try and make some cattier bucket panniers this weekend, just because I too have several stacked up in the shed. I will post back here about my success or failure. Hope these links help you