Being that my old panniers were beginning to fall apart, not weatherproof, generally unsatisfactory, and quality new panniers (like everything else cycling) are overpriced, I made my own.
Now that I have test flown them for a couple of weeks, and they work to my satisfaction, it's time to share.
Now part of this idea I did not plagiarize from one of our fellow forum members. I blatantly, outright, stole it. And I would be more than happy to give credit where credit is due, if I could only find that thread again. So if you see your ideas used here, sound off.
This photo shows the completed product.
Using this box:
http://www.basspro.com/webapp/wcs/st..._SearchResults
The hooks, bungee and and retaining line for the latch clips came off my old panniers. The hooks are attached with 3/16"x3/16-1/4" grip range aluminum pop rivets, and backed with back-up plates. These are the shortest rivets I would use for this, slightly longer would also work.
The latch clips are to keep the boxes from popping open and scattering their contents all over the road in case I do a surface density test of the pavement.
One on the bike.
Here you can see the rubber bands I made from an old inner tube around the hooks and rack to keep the panniers from bouncing off. A carryover from my old panniers. These clips from MEC would probably be better.
http://www.mec.ca/Products/product_d...=1219620918746
You can also see how the 3", nylon, open base, cleat mates with the rack to keep the box held in tight to the rack. I attached the cleats using stainless screws, flat washers and locking nuts. Although stainless probably wasn't necessary for this. Each nut has an oversized flat washer, followed by a smaller flat washer under it.
The bungy attaches through the hollow base of the cleat, held in place by a simple stopper knot.
Rear view.
Showing the DOT C-2 reflective tape.
Front view.
The panniers are mounted so high so that the rivets don't interfere with the removable tray that goes in the top of these boxes.
They are mounted so high and far back on this bike to avoid heel strike when this rack and panniers are on my road bike.
Total cost was less than $20 apiece, $40 for the pair.