My bucket pannier build
 

Well, I've gone and went MacGyver this weekend and built me a pair of bucket panniers. I took the basic design from crazyguyonabike.com, adopted a modification of the tensioner, and adjusted to the hardware I could find at Home Depot and Lowe's.

Hardware List

• 2 4-gallon square buckets with lids
• 4 3/8" fender holders, stainless steel
• 8 #10-24x1/2" cap screws, button top, stainless steel
• 8 #10-24 nylon lock nuts, coarse, stainless steel
• 8 1/4" cut washers, stainless steel
• 8 #10 cut washers, stainless steel
• 4 1/8" wire clamps, stainless steel
• #8 8-32 nylon lock nuts, coarse, zinc (should be stainless steel, oops ;))
• 2 24" bungee cords
• 2 2" S-hooks
• 2 3/8" cable diameter cable clamps
• 4 3/8"-16 nylon lock nuts

Instructions (For complete illustrations, click here.)

1) Mark cut lines on upper flange for fender holders.

2) Cut through marks and remove flange between cut marks flush with bucket.

3) Mark holes for fender mounts.

4) Drill holes for fender mounts.

5) Insert #10-24x1/2" cap screw through #10 washer, fender mount, bucket, 14" washer and secure with #10-24 nylon lock nut using 1/8" allen wrench and 3/8" wrench.

6) Check for fit.

7) Mark location of lower rack hook points.
http://lh3.ggpht.com/eric.speas/SJie...4/100_2828.jpg

8) Mark holes for 3/8" cable clamp.
http://lh5.ggpht.com/eric.speas/SJie...jpg?imgmax=512

9) Drill holes for cable clamp.

10) Spread ends of 1/8" cable clamp U-bolts slightly to accommodate #8-32 nylon lock nuts using vise grip pliers and needle noose pliers. Be careful not to damage the threads.
http://lh5.ggpht.com/eric.speas/SJie...jpg?imgmax=512

11) Dry fit the #8-32 nylon lock nuts to 1/8" cable clamp U-bolt to check for fit and clearance. Adjust furhter, if needed.

12) Using modified 1/8" U-bolts, mark holes on sides (front and back) of bucket between the top flange and the top of the bucket.
http://lh5.ggpht.com/eric.speas/SJie...jpg?imgmax=512

13) Drill holes for 1/8" U-bolts.

14) Using the bungee cord hook as a guide, adjust the nuts that came with the 1/8" cable clamps to allow enough room for the hooks.
http://lh4.ggpht.com/eric.speas/SJie...jpg?imgmax=512

15) Insert 1/8" U-bolts into holes and tighten with #8-32 nylon lock nuts using 11/32" nut drive and a cresent wrench. (Hint: Tighten the inner nut first. You will not need to other part of the cable clamp.)

16) Mark cut lines on upper flange for bungee hooks.

17) Cut away excess flange between marks.

18) Insert bungee cord hooks into 1/8" U-bolts, check fit, and adjust as needed.
http://lh5.ggpht.com/eric.speas/SJie...jpg?imgmax=512

19) Using vise grip pliers, crimp one end of S-hook around bungee cord.

20) Route bungee cord between 3/8" U-bolt and the lower clamp piece, leaving hook below the clamp and secure with 3/8"-16 nylong lock nuts using 9/16" socket wrench.
http://lh3.ggpht.com/eric.speas/SJie...jpg?imgmax=512

21) Test fit pannier on rack.

22) Check lid for fit. Cut notches for clearance around U-bolt nuts, if needed.
http://lh6.ggpht.com/eric.speas/SJie...jpg?imgmax=512

Completed Project
http://lh3.ggpht.com/eric.speas/SJie...jpg?imgmax=512

Very Nice!! Where did you get the buckets and Fender Holders? I was going to use kitty litter buckets but don't need the litter and would rather go without the logo.

You can get used square buckets from restaurants - bulk condiments like pickles and mayonnaise come in buckets that size.

Nice panniers, Harleyfrog! They look every bit as good as this, without the cost: http://www.nashbar.com/profile.cfm?c...20Frame%20Bags

Hehe nice, I was thinking of doing makeshift bucket panniers but I went with a milkcrate instead.

Think of the clearance issues! Especially in tight traffic! :eek:

Slap a couple of slow-moving-vehicle triangles on the backs and take the lane :D

Actually, the whole deal isn't that wide - anything that gets close enough to hit the buckets is within a couple of inches of hitting your body anyways.

Nice! I made a pannier out of an old messenger bag, 2 s-hooks, a piece of steel, bungie rope, and some misc pieces of nylon. It actually works reasonably well and doesn't look too ghetto. I am now inspired to make bucket panniers.

Now the time to find some primer to treat the plastic and paint them the same color as your bike.

I think it's pretty cool way to save money...

Is it wider than the handlebars though? The main problem is that I judge gaps to be big enough by seeing if my handlebars would fit through it... I'm more afraid of me getting one of the buckets caught on something while I'm trying to cut it close to something (you know me, living on the edge of danger).

And +1 on painting it... except matching it to your pink/purple bike scheme...

Many of us never ride through "gaps". These are no wider than if I put both panniers on my bike.

Sorry, I couldn't resist...

http://paulstamatiou.com/wp-content/...ns3_bucket.jpg

Thanks for the complements. I had fun building them. :) Let's see, to try and answer everyone's questions, in order.

KLW2: The buckets are kitty litter buckets. Bought them at Pet Smart (we have two cats) and the label was just a plastic sleeve that came right off (bonus!). The fender holders I found at Lowe's in the Hardware/Small Parts (where you'll find the nuts, bolts, etc.). I was looking for single hook rope cleats, but the only ones I found were too big. The fender holders are, I think, much better.

illdoittomorrow and schu777: I ordered a red reflective sheet (10"x24") from StreetGlo and should have it on the back of the panniers by this weekend. The only problem with painting these particular buckets is the type of plastic. They're made of high-density polyethylene (HDPE) and polyethylene can be very difficult to get maximum paint adhesion. Polypropylene (PP) is also commonly used in making these kind of buckets and is easier to paint. I was going to paint them (red on the back, yellow on the sides, white on the front) and put a reflective top coat on them, turning them into oversized reflectors, but the reflective sheets will also do the job. Also, I'm think of adding red strobes on the backs to add som active lighting. ;)

ShadowGray: The bucket panniers are just as wide as my handle bars. (Actually, measuring the from the bar ends, the handlebars are slightly wider.)

Also, I took into consideration heel strike, which is why I have the large cable clamps off-set towards the front of the bike. :)

You can always use laundry detergent and the nice buckets that comes in when buying bulk.
http://i143.photobucket.com/albums/r...u/HPIM0387.jpg

Steel wool takes the labels right off.
http://i143.photobucket.com/albums/r...u/HPIM0388.jpg

I use 1' aluminum angle as the support bracket and hooks. A ball bungee around the handle and hooked to the bottom of the rack hold it down. Also note the #8 "U" nut, a #8 wood screw keep the bucket from jumping off the rack when hitting a pot hole.
http://i143.photobucket.com/albums/r...zou/bucket.jpg

OH! the FREDishness of it!
http://i143.photobucket.com/albums/r...u/HPIM0394.jpg

Nice job!!

This might work for painting.

http://www.krylon.com/products/fusion_for_plastic/

My friend uses these!

Where did your friend get camouflage buckets?

About bucket alternatives, something I have bought (but not yet assembled) is a drybox from a store that carries outdoor camping/hunting equipment. Try this link to the manufacturer's website to see an example: http://actionp.thomaswebs.net/catalog/18.html
This website calls them "sport utility boxes." Here is where their product can be bought: http://www.actionp.com/WheretoBuyActionProducts.html
Mine cost me about $16.

Things I like about dryboxes are:
1. the dimensions are more rectangular so the boxes don't stick out so far
2. the lid is on a hinge, has a gasket making a watertight seal, and has a latch which will even take a lock if you like
3. the ones I found come in olive drab (green), white, or orange. By the way, the label on the side in the picture below peels off.

Here's another example of one, this one from Northern Tool:
http://www.northerntool.com/images/p...s/26170_lg.jpg

Do you know what type of plastic it's made from? (There may be a symbol like this on the bottom.)

Harleyfrog, I will try to remember to check for the kind of plastic material tonight after work. I have the box at home right now.

^^^^ Cool, thanks. :)

I love these DIY threads. I'm considering going with a milk crate instead of buckets, but that'd be just for carrying my lunch w/o crushing it w/ bungies.

I carried my lunch in one pannier and my work clothes in the other. Of course, my lunch was in a soft-sided cooler. These buckets are HUGE. (okay, maybe not that big, but they do hold a lot. ;)) And, I still have the option for a trunk, should the need ever arise.

The mile crate idea is cool, but I'd opt for a bungee cargo net on top, just so things don't disappear en route, especially on one road I ride. :lol:

The only bad part of my ride:
http://lh4.ggpht.com/eric.speas/SHI8...jpg?imgmax=512

How's the water-tightness with the covers on? I've always been intrigued by the homemade pannier!

Don't know, yet. Haven't had a wet ride (yet). I only rode with these panniers once, but the lids are fairly tight, but not 100% waterproof. MNBiker's idea, tho, sounds promising for being waterproof.

HAHHA I did that with some metal ammo cans. But not on a commuter, it is on a military themed cruiser that I am building.
http://i120.photobucket.com/albums/o...0730081149.jpg

Now THAT would look awesome on a Kona Ute.

http://www.konaworld.com/bikes/2k8/i...25/2K8_UTE.jpg