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Old 11-03-08, 08:28 PM   #1
ProsecutedBiker
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Corrugated Plastic Panniers

Well I have been looking for cheap (i man under 10$) panniers, and have been unable to find any. With Election day just a couple hours from starting I thought that I would try making myself some panniers. Out of what?

Coroplast! Thousands of Soroplast signs litter the sides of the streets, and since the election will soon be over, there is no need for them. I will be collecting some and trying to make panniers out of them along with some cloth, duct tape, and other cheap materials i can find.

Wish me luck
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Old 11-03-08, 08:49 PM   #2
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Take pictures! Sounds like a cool idea.
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Old 11-03-08, 09:49 PM   #3
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sounds cheap!
can't buy even a small seat bag for $10, much less panniers.
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Old 11-03-08, 10:05 PM   #4
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Quote:
Originally Posted by ProsecutedBiker View Post
Well I have been looking for cheap (i man under 10$) panniers, and have been unable to find any. With Election day just a couple hours from starting I thought that I would try making myself some panniers. Out of what?

Coroplast! Thousands of Soroplast signs litter the sides of the streets, and since the election will soon be over, there is no need for them. I will be collecting some and trying to make panniers out of them along with some cloth, duct tape, and other cheap materials i can find.

Wish me luck
Duct tape and other adhesive tapes don't stick to Coroplast well. The adhesive tends to slide off, leaving an ugly, gooey mess.

I've heard of people sewing Coroplast together with dental floss, but I had good success with zip-ties. A few years ago I built a couple tailboxes for my recumbent, and I wrote up instructions:
http://home.comcast.net/~jeff_wills/tailbox/index.htm
http://home.comcast.net/~jeff_wills/tailbox2/index.html
These can be easily adapted to upright use.

Have fun! After Tuesday, it's Coroplast harvesting season!
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Old 11-03-08, 10:07 PM   #5
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Good idea, post whatever you come up with. Mebbe some helpful fasteners- zip ties, of course. And maybe some nylon string, or light tie wire, or old string trimmer string for lacing things together. Use an awl(or whatever you have) to poke holes for lacing.

***Edit- Ahh! Jeff beat me to it!
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Old 11-03-08, 11:20 PM   #6
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square buckets work well and are far stronger.
http://www.cobbworks.com/
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Old 11-04-08, 12:16 AM   #7
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Thanks for the tip on the duct tape, maybe i'll use the plastic tie idea.

And as for the buckets, I really want something thinner and lighter, because my bike is heavy enough as it is

And just to warn you guys wanting updates, I may not be able to start until this weekend. I have LOTS of homework

Last edited by ProsecutedBiker; 11-04-08 at 12:27 AM.
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Old 11-04-08, 12:29 AM   #8
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I don't know if the stuff will hold up or not. it's not all that strong.
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Old 11-04-08, 12:36 AM   #9
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I was planning on reinforcing the bottom with something stronger.
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Old 11-04-08, 12:40 AM   #10
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also the side so it would hold hooks. now the buckets start looking good (G) hey get the bucketsd and cut out excess plastic. need it dry line it with a plastic bag.
the buckets work well till you can afford the real thing.
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Old 11-04-08, 04:12 AM   #11
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The Coroplast king is Kent Peterson. Handlebar bag here:

http:\\kentsbike.blogspot.com/2007/08/coroplast-handlebar-bag.html

might give you some ideas. He also fashioned some fenders from Coroplast.

Unfortunately, the links to the mile43 website where the instruction originally appeared seems to be broken. But you can probably email him for details.
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Old 11-04-08, 11:47 AM   #12
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Carradice panniers use coroplast as the stiffening board on the base and back. They rivet it to the canvas through the mounting rails. Their bar bag is a coroplast box with a canvas coating, held by rivets. Even without the canvas, the corrugated plastic is really tough, strong and durable. If you double up the base and use x-ply directions it gets much stronger.
You can make flat-folding shopping baskets with zip-tie hinges. With so much material you can experiment with non-square profiles for added heel clearance.
Post some pics please..
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Old 11-04-08, 12:13 PM   #13
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Fishing line, use a small finishing nail to make the hole. If you can not find a nail in the junk drawer, use the one holding a picture to the wall...

Good luck, love to see a picture.
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Old 11-04-08, 03:54 PM   #14
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Seen a piece on this somewhere - no idea where, so this post is pointless
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Old 11-04-08, 04:13 PM   #15
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Where does everyone get coroplast from? I've searched everywhere and the only campaign signs I've found are made of paper-like plastic suspended between wire poles.
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Old 11-04-08, 04:27 PM   #16
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Pop rivets with largish washers works really, really well for corrogated plastic.

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Old 11-04-08, 06:05 PM   #17
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Unless you want the activity of doing a box like this it's way smarter to re-purpose an old suitcase
or bag to this task to save the $$$$$$$$>
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Old 11-04-08, 08:26 PM   #18
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I walked past the polling place just now while walking the dogs. About 2/3 of the signs were the plastic-on-wire, but there were some coroplast signs there as well.

They DO sell blank coroplast signs at Lowe's. I don't remember the price, and it may be too high to be worth using. (They also sell all sizes and shapes of plastic bins, tubs, and buckets).
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Old 11-05-08, 10:24 AM   #19
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Thanks for reminding me!

I'm going to go out looking for political campaign signs, as soon as I'm finished with my coffee...
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Old 11-05-08, 11:50 AM   #20
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use metal rivets and washers to slap it together.

ooops ...I just read he above post about that...so


+1
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Old 11-05-08, 01:24 PM   #21
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THANK You, for reminding me to go out and get some post-election free Coroplast!

I managed to get three signs.
One of them is eight foot by two foot,
(but I cut it in half on-site)

The other two are four foot by four foot.

I'm going to put together a set of Coroplast panniers for my semi-recumbent's rear rack.
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Old 11-05-08, 02:50 PM   #22
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Making progress on the panniers.

I went to the hardware store to get a yardstick and a Sharpie marker.

Using a 2 foot by 4 foot piece of coroplast, I marked the centerline.

The rear rack is 5 and a quarter inches wide. Is that standard?

...

The sheet is marked for bending and cutting. I made the first two bends, so the piece will go over the rack, by lining the piece up over the edge of a short piece of I-beam. I had to put the I-beam 'anvil' on top of a wooden box, to get enough room to bend it. The corogations run side to side.
The boxes will be 14 inches long x 8 inches deep x 5 inches wide.

I have a cordless drill to make holes, and I intend to fasten the pieces together with zip-ties and packing tape.

I didn't mean to hi-jack this thread, but as I said THANKS in capital letters for reminding me to go out and get the free Coroplast, available only the day after Election Day.

Do you want pictures? I don't have a digital camera.
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Old 11-05-08, 04:12 PM   #23
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Finished!

The panniers came out beautiful!

The Coroplast was harder to bend than I anticipated, especially against the "grain".

The left pannier says "COURT JUDGE" on it in big red letters. That's the way it came out. I wonder if I should paint over it, if possible , or leave it. Might give some daredevil motorists something to think about (jail time).

I will try to take pictures , but don't hold your breath.
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Old 11-05-08, 04:18 PM   #24
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you needed to cut v grooves in it so it can bend.
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Old 11-05-08, 04:46 PM   #25
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For bending against the grain, it might help to crimp it with a straightedge or before bending- just smush it flat in that area?
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