Project Continued:

8) The Corrugated Plastic Board all cut out, ready for Creasing and Folding:


9) Creasing the Plastic Board- Use BOTH Hands, press hard, with the FOLD Line aligned with the Wall Corner on the back of a Closet. It takes firm , even pressure to crease the Coroplast Plastic Board (I had to use my other hand to press the camera button, this photo was taken after the crease was made):


10) Fold the Pannier into its proper shape, and tack it with a piece of packing tape. Then drill holes, and start threading in some Nylon Zip-Ties. You may wish to substitute Pop-Rivets with washers. I prefer Zip-Ties as I can make an emergency repair on the road. If you carry a Pop-Rivet Tool on your Bicycle for emergency repairs, do your own thing:


11) A third-hand Brake Cable Tool is useful for tightening the Zip-Ties:


12) Left Side Pannier is done:


13) Both Pannier Sides are done, assemblage is upside-down on the floor:


14) Old Panniers on the Left, New Panniers on the right. The new Panniers are about twice the cubic volume, although two inches narrower overall. The old were 7 inches deep, the new are 12 inches deep. The old were 14 inches long, the new are 18 inches long:


15) Test Fitting. I was inspired by TWO things- A motorcycle I saw last night, and a recent thread about a heel-clearance problem with rear panniers (here at bikeforums dot net). The SLANT allows for heel clearance, even with the panniers all the way forward on the rack:


16) The Mounting Bolts are inserted from underneath, and large fender washers were used, to protect the Coroplast (tm) Corrugated Plastic:


17) THE END:


I hope you have found this How-To Guide Useful. I wanted to say at the beginning that the set of Panniers would be made from a SINGLE SHEET of Plastic, using a method like Origami, or building a Paper-Airplane.

There are other photos at my web page, which didn't get selected for use in this How-TO Guide, if you feel like looking at them:
http://s134.photobucket.com/albums/q119/hotbike/