Advertise on Bikeforums.net



User Tag List

Results 1 to 12 of 12
  1. #1
    Senior Member
    Join Date
    Oct 2007
    Location
    Washington, DC
    My Bikes
    CAAD10 5, Trek 1000 Alpha Series
    Posts
    454
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)

    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!

    photo.jpg

  2. #2
    Senior Member Ranko Kohime's Avatar
    Join Date
    Jan 2012
    Location
    Cincinnati, OH
    Posts
    108
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    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.

  3. #3
    Senior Member
    Join Date
    Sep 2006
    Posts
    887
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    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.
    73 Raleigh 20
    85 Trek 300 series
    05 Kona Caldera
    05 Surly Cross Check
    09 Giant Trance X2
    12 Tern Link P9

  4. #4
    joel52
    Join Date
    Apr 2012
    My Bikes
    2012 Raliegh Misceo
    Posts
    86
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    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.

  5. #5
    Thread Killer
    Join Date
    Aug 2008
    Location
    Ann Arbor, MI
    Posts
    2,978
    Mentioned
    4 Post(s)
    Tagged
    0 Thread(s)
    This guy may have some ideas for you, based on his CoroPlast fairing constructions:
    http://www.ihpva.org/Projects/WVolk/...anchor32518877
    Chaad--'95 DeKerf Team SL, '02 Lemond Buenos Aires, '05 Novara Buzz, '73 Schwinn Collegiate, '06 Mountain Cycle Rumble, '09 Dahon Mariner D7, '12 Mercier Nano, '12 Breezer Venturi

  6. #6
    Senior Member
    Join Date
    Mar 2009
    Posts
    65
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    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.

  7. #7
    Thread Killer
    Join Date
    Aug 2008
    Location
    Ann Arbor, MI
    Posts
    2,978
    Mentioned
    4 Post(s)
    Tagged
    0 Thread(s)
    Quote Originally Posted by hopperja View Post
    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!
    Chaad--'95 DeKerf Team SL, '02 Lemond Buenos Aires, '05 Novara Buzz, '73 Schwinn Collegiate, '06 Mountain Cycle Rumble, '09 Dahon Mariner D7, '12 Mercier Nano, '12 Breezer Venturi

  8. #8
    Senior Member
    Join Date
    Apr 2011
    Posts
    209
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    +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.

  9. #9
    Senior Member
    Join Date
    Oct 2007
    Location
    Washington, DC
    My Bikes
    CAAD10 5, Trek 1000 Alpha Series
    Posts
    454
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    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!


    photo(1).jpg

  10. #10
    Bicycle Lifestyle AsanaCycles's Avatar
    Join Date
    Jan 2008
    Location
    Pacific Grove, Ca
    My Bikes
    Neil Pryde Diablo, VeloVie Vitesse400, Hunter29er, Surly Big Dummy
    Posts
    1,737
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    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/

  11. #11
    Beast Rider BeastRider's Avatar
    Join Date
    Oct 2011
    Location
    Newport News, Virginia
    My Bikes
    Trek Transport
    Posts
    274
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    Quote Originally Posted by chaadster View Post
    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......

  12. #12
    Senior Member
    Join Date
    Feb 2001
    Location
    England
    Posts
    12,073
    Mentioned
    2 Post(s)
    Tagged
    0 Thread(s)
    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.

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •