venturi95

I am trying to think of ways to eliminate the low-level but incessant rattling of panniers on racks. Buying new gear is out of the question. I am using a near-new set of Overland panniers from the 1990s that hook over the top rails of the rack, and bungee tensioners keep things from ejecting skywards. Before I head to the hardware store and take a drill to the back plates I thought I would tap into the cosiderable brain power here. Any suggestions or experience would be appreciated. I avoid touring in the rain, so water proofing isn't a huge issue. I keep my load lighter than most.

10 Wheels

Your hooks should be mounted with rubber in between the racks.
Use a piece of inter tube if there is no rubber on the hooks.

venturi95

Racks are of the 10mm variety, hooks are coated with rubbery substance.

LeeG

long 24" or so bungie going from bottom of rack strut over the pannier and onto the rack in such a way that if the panniers hit a hard bump the clips can't unhook. I do that to keep panniers flat when empty and keep pannier and contents from wiggling around when riding.

Bacciagalupe

I've never had an issue, and that's with using 3 different set of panniers (cheapo Cannondales, Deuters, Ortliebs)

I hate to break it to you, but if you need to use bungee cords to keep your panniers on, then yeah it sounds to me like it's time to get a new set.

You can get affordable panniers from Nashbar for as low as $30 a set, so I don't see why replacements should be off the table.

fietsbob

consider backing up or replacing the bungee hold down with something rigid.
like a strap and buckle.. My Beckman Needle works panniers use a buckle and strap
to pull the hooks down firmly , no bounce or rattle ..

I have an Older set of Ortliebs to they use a buckle and a J hook
at the end of an accessory strap , is sort of belt and braces for the locking
hook system, so they dropped it from subsequent top hook molds that make the current stuff..

You .. too ... can fit a Buckle and some webbing, to the inside face
of your existing panniers ,
Using nuts/bolts or pop-rivets.

bktourer1

You could try geting an old tube, cutting it into strips, and wrap around the pannier racks

Yan 

The bungie chord should be under considerable tension at all times. My panniers have long lost the rubber coverings on the hooks, but are quiet.

fietsbob

FWIW, Bungee cord by the yard, FS at REI, ..
I have used Hot-melt glue and Heat Shrink tube
to finish the ends of the stuff.

bradtx

venturi95, Go to the hardware store and get this https://www.plastidip.com/ to coat the upper hooks with.

Brad

c3hamby

wrap the racks with duct tape?

Booger1

If the hooks are too big for the rack,vacuum tubing from the auto parts store,cut into a spiral,wrapped around the rack.Comes in all sizes,tough,won't fall off.

Make sure the bungie,strap,spring,ect. on the back of the pannier runs through a support or two(between the upper hooks and lower hook) before hooking to the bottom of the rack.

indyfabz

Cloth tape, such as the stuff used for grips of tennis rackets, where the panniers and contacting the racks?