Utility Cycling - DIY Coroplast Panniers: Need some advice!

I decided to make some coroplast panniers to put on my beater for grocery runs but I think I need a little help. Each wall of the pannier is reinforced with two pieces of coroplast held together with zip ties. I originally wanted a hook mounted system but everything I tried was not sturdy enough. I've decided that I'm probably just going to have to attach them to my rack with zip ties but I'm slightly concerned the weight of groceries, etc will tear the walls of the coroplast. Anyone know what I can use to reinforce it? I was thinking of adding some more coroplast to the wall being attached and maybe some duct tape around the whole pannier. Suggestions welcome!

252009

I wouldn't think any of those solutions would hold up to groceries, depending on how much weight we're talking about.

My solution would be to get an angle-aluminum, and make a skeleton frame, to which the Coroplast then gets attached, acting as the body of the pannier.

Coroplast is amazingly durable and there's no way groceries are going to out-match coroplast. Zip ties and coroplast should be sufficient to make a set of bins to carry home some groceries. I use coroplast as the floor of my BAW 64a trailer. Granted it's double layer and I take care of it, but I've had ~400 pounds on it with no problems. Coroplast is underrated for bicycling applications.

Regarding the hooks, search "Stanley-National Hardware Blunt End Tarp/Rope Hook". I got some at Lowe's for $0.76 each for DIY laptop pannier and kitty litter buck pannier. I pinched them in a vise for a slightly narrower opening but it wasn't really necessary. Jandd and Axiom, at least, sell pannier hooks (rubber coated) in the $5-15 range.

This guy may have some ideas for you, based on his CoroPlast fairing constructions:
http://www.ihpva.org/Projects/WVolk/index.html#anchor32518877

I'd want to reinforce the holes you're zip tying through. Maybe with a piece of AL strap which is in turn pop riveted to the coroplast (with backing washers) Bottom line is you want to distribute the weight of the load over a large surface of the coroplast not just one or two holes.

I use coroplast as the floor of my BAW 64a trailer. Granted it's double layer...
I think that's a great idea that more people need to know about. I'm consistently horrified by the guys in the Utility Forum who use plywood for floors, as if weight doesn't matter. Sorry for the thread drift, but I'm delighted to hear of someone thinking outside the box!

+1 You can use aluminum, or a stronger rigid plastic. You want to distribute the stress of the attachment across as much of the coroplast as possible.

Well after some reinforcement I decided to put one on the rack and see how much it could hold. I put 26 lbs of freeweights in it and let it sit for an hour and a half and so far so good! Obviously riding aroudn with it will be different but I'm certainly not planning on putting that much weight in each pannier. Thanks for all the suggestions!


252235

here is something interesting.
http://thelazyrando.wordpress.com/2011/05/16/

coroplast is amazingly versatile
I used to use it for R/C airplanes. here's some info: http://www.mugi.co.uk/tutorials_evostik.php

and of course coroplast is available in a variety of sizes: http://www.coroplast.com/catalog/coroplast/

I think that's a great idea that more people need to know about. I'm consistently horrified by the guys in the Utility Forum who use plywood for floors, as if weight doesn't matter. Sorry for the thread drift, but I'm delighted to hear of someone thinking outside the box!

I agree. I have used coroplast for a few things on ""THE BEAST"" as well. Also, just for looks mind you, I found some wood look paneling that worked out much better for flooring on my front and rear racks. I never considered using plywood as I knew that would add far too much weight.

Coroplast can be good for some applications but I am not too sure about using it for anything with any serious weight......

Carradice canvas panniers use a coroplast back and base. The mounting system is an extruded aluminium rail, rivetted in 3 points to the coroplast (through the canvas). Rixen and Kaul hooks are slotted and positioned on the rail.
The single thickness coroplast supports all the weight and provides all the support for the rivets. The canvas provides external abrasion resistance and stops stuff falling out.
My 1995 vintage Super-C panniers are still in good shape and the coroplast has a decade or 2 of life remaining. They are the std model for heavy duty touring.
Using wood or aluminium panels for bike luggage instead of coroplast adds nothing to the strength or durability, only to the weight.