Decided to make my own Panniers! - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 13 Old 10-29-2016, 07:54 AM Thread Starter
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Decided to make my own Panniers!

After looking into panniers for my KLR and realizing what they cost, I've decided to make my own. In a nutshell the plan is 3/8" ply, hybrid channel for the lid, two coats of gel coat and finished with a line X spray. Will be relatively light and bullet proof. Haven't picked out my latches yet but here are some pics. At this point they're ready for the lineX. At this point I have only spent $13.00. my neighbor owns a lineX so I'm hoping for a better deal. If not I'll use Duplicolor bed armor to make sure I like them before spending the money.

More piks as I progress...

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post #2 of 13 Old 10-29-2016, 09:30 AM
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I like that! A creative solution to costly panniers! They wont rattle like the aluminum ones either. The only thing I would maybe worry about is durability in a fall, but I guess repairs would be fairly easy to carry out if that did happen. Looking forward to the finished pics!

They do look great, I can't even cut a board the right length without messing it up, so I appreciate the craftsmanship

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post #3 of 13 Old 10-29-2016, 10:03 AM
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Very nice Craftsmanship Sender1.

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post #4 of 13 Old 10-29-2016, 04:53 PM Thread Starter
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Thanks , appreciated... I've run a fab shop for the past 12 years so it helps to have access to products not sold at local stores. As to the fall factor,. I know if I go down they're going to splinter like toothpicks buy on the upside it took me about 4 hours to build. I'm pretty stoked about them so far. Just added the hinges...

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post #5 of 13 Old 11-10-2016, 08:45 PM Thread Starter
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Just thought I'd share some piks of the final product.


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post #6 of 13 Old 11-10-2016, 08:47 PM Thread Starter
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The top bag is soon to be replaced with a matching case. I'm pretty happy with the way they turned out.

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post #7 of 13 Old 11-17-2016, 08:45 PM
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What a great job!!!
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post #8 of 13 Old 11-17-2016, 11:09 PM
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That is a beautiful job Sender1!!
If you can swap them from one side to the other(hinge forward) It will prevent the lid from being torn off by the wind if a latch is left open. Don't ask me how I know this!!
JJ

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post #9 of 13 Old 11-20-2016, 06:41 PM
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Does the aluminum channel have a specific name or is it a specialty item you came across?
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post #10 of 13 Old 11-20-2016, 07:10 PM
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Wow, those look amazing! You should sell some. If they only cost you $13 and alternatives cost ~$400, you could beat the competition and still make a good buck.
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