I figured I would put this in touring section, as this would be the area with the most pannier experience. I have recently tried nashbar ATB panniers, and the waterproof ones. both sets self destructed, one actually braking off after I hit a bump and dragging beside my bike a short bit. Luckily, it didnt cause me to crash, as cars were passing me at about 45mph.

After the problems I had with those, I decided it was either expensive panniers, used panniers, that I get outbid for on ebay, or see if I could do something at home. My sister has been sewing and creating costumes, bags, blankets and other items for years, and she said she would be up to the challenge. What im looking to do is find the right materials. I have found a couple of sights that sell the main material for the bag and straps, but I was wondering if there were good places to get specialty zippers, and the actual Hooks to mount it to the rack. If anyone has any ideas, I would appreciate the input. Also, any suggestions for this attempt would be appreciated.

Things I need:
Bag Material--Have a resource already
Zippers
Clasps for locking down covers--Have resource
Hooks and locking mechanisms for the back of bag--EDIT seems jannd sells this stuff
Suggestions for the backing of the bag to allow it to be more rigid
Information on taping of the seems. (maybe my sister knows)
Types of thread (again sister may know already)
Anything else you can think of (besides that I may be wasting my time)

If this works out, Ill post pics of what we come up with.