Cutting Brooks Bags
 

Many people cut and modify their Brooks saddles, both in the pursuit of fashion and hopefully some added functionality.

My dad bought me a set of Brooks Brick Lane Roll-Up Panniers for Christmas. I warned him beforehand that I had every intention of cutting them apart with the plan to turn the connected bags into traditional separate panniers.

Here they are prior to separation. More images on the way shortly.

http://i130.photobucket.com/albums/p...106_135249.jpg

http://i130.photobucket.com/albums/p...106_134905.jpg
The left bag is sitting crooked because of a taillight mounted to the rack. This gets addressed later on.

I'm looking forward to seeing the end result!

So, what kind of bike is that? Is there a thread somewhere on it? :)

Nice looking ride, can't wait to see how you make two bags from the one. Looks like you have a warehouse for indoor riding too. I love indoor warehouse racing ;-)

This bike spends too much time in that shop. :(

It most likely began life as a bare mountain bike frame that was only available in the 1983 Schwinn catalogue. I bought it about 5 years ago as an emply frame after having been a complete bike at least once in its life. My original build was intended to be a more modern interpretation of the English 3 speed. As many "street rod" projects go, ideas kept coming and things kept going.

The long, tedious ID and subsequent build thread is here. I'll add the bag build images to it soon.

Brooks intended for the bags to connect to a rack with four straps located on the underside. The 4" middle connecting panel includes a bungie strap and an internal aluminum frame to carry things, such as this conspicuously placed erudite European newspaper next to a fresh baguette.
http://i130.photobucket.com/albums/p...psd1b7347e.jpg

The leather handle gives one the impression that you can easily detach the bags and carry them into the grocery store. Lovely as it is, this is not the case.

2" wide tape is used to mark the center of the panel for cutting.
http://i130.photobucket.com/albums/p...109_150207.jpg

With the bags free from each other, the grommets get drilled out creating the beginnings of a pocket for an aluminum support bar.
http://i130.photobucket.com/albums/p...109_152438.jpg

The remaining holes get finished off with individual grommets.
http://i130.photobucket.com/albums/p...109_174205.jpg

The cut edges of the pocket need to be folded and hemmed. Being a tough guy, I don't have a sewing machine. So this was hand stitched while watching the original Alien and then Django (1966).

An aluminum bar is cut and the rough edges filed and sanded. The 4 attachment straps, being no longer necessary, are removed.
http://i130.photobucket.com/albums/p...110_203938.jpg

Here is the finished edge of the newly created pocket.
http://i130.photobucket.com/albums/p...110_225046.jpg

You are : Lucky to have a Dad that gets you Brooks items.
: Braver then I to do that to a Brooks item
: Quite talented to do that with a Brooks item

So far looks like an interesting alteration. Will check back in for your further work. Nice !

I was sent a Swiss canvas ammo bag from Germany and modified it for one of my MTBhttp://bikeforums.net/attachment.php...hmentid=294594http://bikeforums.net/attachment.php...hmentid=294595Brown leather belt got turned into straps and attached to the bag with brass hardware. Then it gets put onto the Vetta rack I have on the Alpina Pro Univega. Still waiting for the leather shops around here to have time to sew buckled straps on it for a more permanent fix.

Nice project you have and looks to go perfectly with that wonderful build.

Panniers need hooks to hang from the rack. Jandd sells replacement clips & hooks for their bags. As many others have done when making their own bags, I ordered a set. An attachement point for a bungie cord needs to be made so the lower hook can grab the lower leg of the rack, as shown here.
http://i130.photobucket.com/albums/p...ps6a5955c0.jpg

The easy thing to do would be to add a pair of D-rings to the top clips. Using stainless steel shim stock and big D-rings, I bent up my own set of loops. The lower loops will hold the bungie hook and the top loops are for a handle or shoulder strap.
http://i130.photobucket.com/albums/p...118_151032.jpg

These loops get bolted onto the aluminum bar hidden inside the top flap of the bag. Also note the large holes to allow use of the grommets.
http://i130.photobucket.com/albums/p...118_165225.jpg

http://i130.photobucket.com/albums/p...118_165600.jpg

The lower hook is secured with a footman's loop.
http://i130.photobucket.com/albums/p...119_194402.jpg

Using rope and a spring, the hanging system is completed.http://i130.photobucket.com/albums/p...119_210052.jpg

These bags are meant to be rolled up when not in use. The flap I created for the support bar covers the metal post that allows this to happen. I removed this post and re-attached it to the aluminum bar. Now the bags can be rolled in this new configuration.
http://i130.photobucket.com/albums/p...119_210150.jpg

Here is the rear of one bag attached to the rack showing the hanging system.
http://i130.photobucket.com/albums/p...119_210342.jpg

The finished bags
http://i130.photobucket.com/albums/p...119_210448.jpg

A fender mounted tail light has been added, so the bags now hang properly.
http://i130.photobucket.com/albums/p...119_212005.jpg

Next is to fabricate a pair of carrying handles that attaches to the top set of loops. I have a plan in mind using thick aluminum rod and stainless steel eye bolts.

I've seen a few of those Swiss bags turned into bike bags. They look great. My build has some color contraints, otherwise those would have been serious candidates for me.

JJVW,

That's quite some pannier workshop you got. Really impressed with how you thought that system out. If I had not seen this thread and looked at your bike, I would have thought it came that way from Brooks. Have you tried it out on the road? What do you think Brooks would say if you showed this to 'em ?:rolleyes:

I had to switch the bag from one bike to another because the GT's frame is only18", good for me to ride but caused heel strike when I went down the road. The Univega bike is 20" so enough room for the pedal rotation.

I thought about getting manufactures clips but wanted to keep this temp solution till I get straps sewed on. One more choice would be to use cheap P-clips from Lowes to attach it.

VERY nice job !

Very impressive work-around. Looking at those pics I kept wondering, what kind of shop is that?
Great job.

My pannier workshop consists of a 175lb steel block that was shipped to me by mistake along with 3 others hidden underneath a wicker chair. However, it does make a wonderful anvil. If you look closely, you will see the mis-measurements and messy metal work. Fortunately, most of that is hidden. Thanks though.

The rest of the warehouse is part of a specialized moving company. That's our crate shop.

The bags were first mounted last night and that tail light rubs the rear tire, so I haven't been able to ride it yet.

Should I let Brooks know that I made their bags better? :)

I'm curious too. Is that VO rack attached to the fenders? Can't see if it is. I'm wondering if you just attached it at the front, as I did to mine.

So, someone shipped you THREE 175 pound steel blocks, by mistake!? Wow...

FOUR 175 pound steel blocks by mistake. An old client of ours bought a fancy wicker chair and had it shipped it to us. Somewhere along the line, the 25lb chair was set on top of a pallet that contained 700lbs of steel, then covered in blankets and everything shrink-wrapped together. There was no address on the steel blocks and the shipper who sent the chair to us didn't know anything about them. Somehow, no one wondered why this chair weighed so much. I've used these blocks as counter weights for some weird rigging, extra weight in the back of a van for winter driving, an anvil...

That is a VO rack on top of a VO fender. That as actually why I wanted to cut the bags in the first place. I didn't want to cover up the oval platform of the rack. The rack is bolted directly to the fender (both holes), with nothing running to the brake bridge.

Hey!!

YOU'RE the one who ended up with my big ol' useless heavy metal blocks!



I love the story/detective work about your frame- it's cool to have stuff like that.

You can have your blocks back if you can get them to Wisconsin on your bike.

Well, I was ready to piss and moan right from the start. I am applauding now that I have seen the after pictures. Really nice job! With skill like those, you can start your own bag company and put Brooks to shame!

Very nice work. They look perfect.

JJVW,

By all means, let them know. They don't have hit squads......;)

Looks great! But I have one question, what is in that coffin??

http://www.newenglandcountrybakers.c...012/Django.jpg

What's in your guitar case?
http://www.lobshots.com/wp-content/u...l_mariachi.jpg

Email sent. We shall see what happens. Maybe next year there will be new version of these bags for sale!

I'd be surprised if they even respond. You've out done them.

That went from "oh no don't" to "awesome, dude, great work!" pretty fast.

Interesting, more pics please.

Great work. My only concern would be the rubbing on the underside from the lock nuts. I am not sure what they are called but you might think of using those screw on rivets people use when recovering saddles. They have a much smaller profile.