Home made aluminium panniers

[Can samui]

Oops.....almost forgot the obligatory Thailand sticker!!


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[Can samui]

HAHA!
Fear me you mortals for I can now braze aluminum!
I have stared into the eyes of failure and said no.....not today!


Ok ok......I have also created some modern art but hey, cant bake a cake without breaking a few eggs right?
These are the mounting brackets that will be attached to the boxes and hook on to the frames.
Oh yeah.....the frames.....right.
Admission time troops. I fiddled for a while and was just not happy with my efforts so took some aluminum box tube to my local picture frame shop and they made perfect 45 degree cuts then stopped at a welder and dropped them off so I will be getting the structural points TIG welded.
Like momma said, ya cant have everything you want! I may have to content myself with accomplishing some of the brazing. Mission semi accomplished!
Will post picks of the frames when they get back from the welder.


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[AllanB]

How does the gauge (thickness) of the test-piece compare with the box materials?

 

The test material looks quite thick, which I guess would be easier to braze. But the result do look like pretty good.  

[Can samui]

Pieces I have succeeded on are 2mm, same thickness as the sheet I used for the boxes but no way I will even consider trying to braze the boxes, that my friend would lead to suicide, and I have a bbq to go to tomorrow!


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[Can samui]

Racks are back this morning so now I can start mocking up the support system for them.
Planning on two points per rack under the seat and one point on the passenger foot pegs.
Also think the whole rack system will end up matt black in the end.



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[Can samui]

Ok, now that the frames are in I got down to the mounting brackets and latching system.
The brackets are lined with 2mm neoprene to reduce vibration and provide a snug fit.
The latches are the same type as the lid latches and the hooks will be attached after the racks are painted.

Am fiddling with the mounting tabs for the racks themselves......this is going to be interesting to say the least.
I say again, I have no idea what the hell I am doing.


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[thaiguzzi]

No disrespect intended, but that is pretty shltty TIG welding...

[Can samui]

Yep, it is.
TIG welders aren't really on every corner here on Samui so a guy knew a guy with a machine so had to try him out.
It is sturdy, ugly but sturdy. Thus the paint job that will finish everything and hopefully cover up a multitude of sins.


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[Can samui]

Alas, I have not gone round the bend and stare at my navel all day, well....not yet at least.
After some motivational challenges and some engineering failures on the scale of the Russian space program I am finally over the finish line and all is on the bike!






Are they perfect....no. Am I happy with them.....pretty much.
Road test in about 10 days Nakhon Si Thammarat-Krabi-Aonang-Phuket.
If you look close you can see a pure necessity of road trip life.....a bottle opener on the right hand pannier.
So there you have it troops......now what to build next???


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