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Discussion Starter #1
Northern Tool and Amazon sell some nice sport tool boxes that can easily be turned into stylish panniers. The boxes are modeled after ammo cans,

but are made of plastic. The boxes were originally green and I spray painted them black to match the TW.



The reflective tape and optional bullet holes can also be had at Nothern Tool. The next step is to attach the cases to the cycle rack pannier mounting

bracket.







Untitled by rdm2112, on Flickr



Mounting boxes to cyclerack bag supports



Materials:



8 - 1 1/2" x 1/4 carriage bolds

8 - 5/16" washers

8 - 1/4" washers

8 - 1/4" lock washer

8 - 1/4" nuts

2 - Locking Linch Pin, 6/16 in. dia.

2 - 5"x5" 3/4 plywood



Cut some 3/4 plywood into 2 5"x5" pieces









Clamp or hold the wood against the cycleracks bag mount and mark the holes with a sharpie





Using a 5/16" drill bit, drill the marked holes in the plywood



Clamp and center the drilled plywood on the side of the box that will be mounted against the motorcycle. There is a lip for the lid, make sure the plywood is flush with the lip on the box







Drill through the plywood into the box with the 5/16" drill bit.



Clean holes with an knife, removing excess material.







Here is the bolt assembly from the inside of the box, out





Place the bolt inside of the 5/16 washer and push through the box and plywood, repeat for all 4 bolts





Add washer, lock washer and nut to the other side with cyclerack bag mount attached. Make sure you orient it correcly so the the hooks are on the outside and allow you to open the box









Use some paracord or string to attach the linch pin to the closing latch.



Attach bag mounts with box to bike by hooking the bag mounts onto the cycle rack.







I haven't done the shorter turn signal mod, so I used the forward clipping position on the cyclerack.







Here is a front photo. I like that the boxes are low and easily clear my legs when swinging them over the bike.



 

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Northern Tool and Amazon sell some nice sport tool boxes that can easily be turned into stylish panniers. The boxes are modeled after ammo cans,

but are made of plastic. The boxes were originally green and I spray painted them black to match the TW.



The reflective tape and optional bullet holes can also be had at Nothern Tool. The next step is to attach the cases to the cycle rack pannier mounting

bracket.





Pretty Cool...



How do you plan on mounting them? Side or top or cyclerack? Are the side walls of the boxes stout enough to run a bolt thru them w/o any backing? They could mount directly to CycleRacks bag supports.
 

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Discussion Starter #4
Pretty Cool...



How do you plan on mounting them? Side or top or cyclerack? Are the side walls of the boxes stout enough to run a bolt thru them w/o any backing? They could mount directly to CycleRacks bag supports.


I plan on using a sandwich type mount with bolts going through ->cyclerack pannier mount->1/2 plywood->box->backing plate (aluminum or 1/8" steel) in that order. The plywood is needed to clear the lip of the box. I'll post pics when done.



-RM
 

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The nice thing about those is that they can be secured with a small lock in an attempt to keep unwanted visitors out.
 

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When motorcycling I find them vastly preferable to actual bullet holes. Just sayin'.
 

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Since the TW is the Chuck Norris of motorcycles, bullet holes are not a problem.



Oh, and those boxes may be the best value in hard boxes going. I might order a pair, and if they are as good as they look, order a couple more to use atop the rack.
 

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Discussion Starter #11
Since the TW is the Chuck Norris of motorcycles, bullet holes are not a problem.



Oh, and those boxes may be the best value in hard boxes going. I might order a pair, and if they are as good as they look, order a couple more to use atop the rack.


Yea, since the boxes are so cheap ... I could have a "corporate" set with no graphics.



I picked up the bolts for mounting to the cyclerack pannier mount.

I chose 1/4 x 1 1/4 bolts with fender, lock washers and a nuts. 4 bolts in each case box. I think the plastic will be fine with the fender washers.
 

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Discussion Starter #12
And now some fun ... What can I carry in them?



A 1.5 gal gas can





A dumbbell







A pair of hiking boots







2 half gallon beer jugs





Here are my cost estimates ~ 100.00



Cycleracks bag mounts - 52.00

Sports boxes - 28.00

Hardware - 5.00

Reflective tape 5.00

Paint 5.00
 

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Man, those look awesome. I was going to spring $60 for the WalMart saddle bags, but I think I'm going to use your idea. Seems to be more waterproof, hold more, and cost a heck of a lot less. Thanks for posting that.



Dan
 

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Any issues with structural integrity carrying a load? Are you happy with the thickness of the walls of the boxes?
 
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