Jerry (Fuel) Can Panniers
Here is another way to be creative and use generic supplies to make very useful panniers. I saw an original post on the internet that got me started. Checkout this link to see some other ideas.Required parts included:
- Two jerry fuel cans (red to match the bike)
- Four catches for the lids
- One plastic chopping board 8mm thick
- 50mm wide aluminium strip
- Bolts
- 0.6mm galvanised sheet
- Stick on neoprene rubber strip (5x25mm)
- Silicon sealant
The racks I installed on my bike are the SW-Motech racks. They are very strong, Can fit many types of panniers and are also easily detachable. Well worth the money.
The Jerry cans were cut along a line near the top. The plastic was then smoothed off with a fine file.
The next task was to make the mounting points. The bottom of the fuel can just clips over the bottom rail of the rack. I used some kitchen chopping board material for these mounts.
The chopping board is 8mm thick. The bike rack tube 16mm, so This worked out neatly.
Using two coach head (rounded) bolts, aluminium flat on the outside and also on the inside. I tightened the nuts, cut them short and then burred the threads (as good as nylocs!). The bolts were covered with silicon sealant to water proof them.
This inside photo shows the mount point at the bottom with tape over it to stop rubbing.
The mount points at the top needed to be 'lockable' and allow easy removal. I just used two 1/4" bolts with threads cut off and holes drilled for R clips to pass through. These two 'bolts' then pass through the bike rack tube. A small rubber strip between the bike rack and the pannier aids water proofing and cushioning.
The trickiest part was to make the lids. I have seen alloy lids welded up and they look great. I am at home folding sheet metal so I went with that. Allowing the correct amount of gap around the edges so it fits neatly on the fuel cans may be a bit of guess work.
Using 0.6mm sheet I folded the lids with 30mm sides. I rolled the outer edges for a smooth and stronger result. If I made them again I would make 50 or 60mm sides for a little more strength. The joints are pop riveted with silicon sealer to stop water leaks. Flatten the rivets so they have a lower profile.
To seal the lid to the fuel can rim I used a soft neoprene type of rubber strip. Stick on makes it easy to apply.
I fitted lockable catches to the front and back of the lids. These catches can be difficult to source. I found them in a small hardware shop in a small country town. I used pop rivets sealed with silicon sealant. I flattened the rivets in the lid for a lower profile.
No comments:
Post a Comment