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 23 Old 01-16-2017, 06:02 PM Thread Starter
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Panniers

Being a cheap SOB (mama will not let me buy new ones) and the fact I like to build things for my bikes I decided to order some 20MM ammo cans for panniers and make my own racks for them. I found some plans online to give me a starting point then modified those plans to fit my needs. Here are a few pics of the racks before body work and paint. The cans will be here in a day or two and will get a coat of satin black paint to match the racks.



All the corners have gussets for added strength



The rear cross bar unbolts for easy install.




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post #2 of 23 Old 01-16-2017, 06:53 PM
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Looks great!

I picked up a little mig a couple of years ago to fab up some racks for my WR250R, but ended up selling the bike before I got the racks built! Lol

I think the ammo cans will be a nice size, I had big 9 inch aluminum ones on my 08 KLR and they were almost too big unless you were packing for a big trip. Or grocery shopping...

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post #3 of 23 Old 01-17-2017, 10:30 AM Thread Starter
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Looks great!

I picked up a little mig a couple of years ago to fab up some racks for my WR250R, but ended up selling the bike before I got the racks built! Lol

I think the ammo cans will be a nice size, I had big 9 inch aluminum ones on my 08 KLR and they were almost too big unless you were packing for a big trip. Or grocery shopping...
The 20 mm cans show to be 14 1/2 X 8 1/4 X 18 1/2 which are in between the Tusk medium and large cases. Plus I think they will hold up better in a fall.
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post #4 of 23 Old 01-18-2017, 03:39 PM
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Looks great

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post #5 of 23 Old 01-18-2017, 03:40 PM
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Powder coat?

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post #6 of 23 Old 01-19-2017, 03:46 PM
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Good on you for starting out with gussets everywhere rather than searching for a welder on the road somewhere when a joint cracks.

I read many ride reports for information on places to ride. When I see pannier racks at the start, I wonder how long it will be before I read "looking for a welder for my racks". It is not "if" but "when" I will read this.
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post #7 of 23 Old 01-19-2017, 04:17 PM
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Do you know how much the ammo cans weigh? The panniers I made are at 10# each. I'm not sure if that's good or bad but they seem light weight.

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post #8 of 23 Old 01-20-2017, 02:21 PM Thread Starter
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Powder coat?

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Paint for now to make it though this summers rides. Next winter I'll have the racks and cans Ryno Lined.

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Do you know how much the ammo cans weigh? The panniers I made are at 10# each. I'm not sure if that's good or bad but they seem light weight.

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These started at 18 lbs each but I've removed about 3 lbs of extra steal not needed. A little heavier the ones you can buy but at less then half the cost I'll live with it.
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post #9 of 23 Old 01-20-2017, 03:24 PM
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Copy that, good luck with the rest of the build...

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post #10 of 23 Old 01-21-2017, 06:09 AM Thread Starter
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Good on you for starting out with gussets everywhere rather than searching for a welder on the road somewhere when a joint cracks.

I read many ride reports for information on places to ride. When I see pannier racks at the start, I wonder how long it will be before I read "looking for a welder for my racks". It is not "if" but "when" I will read this.
Yea I learned long ago to "Over Engineer" everything so you don't have to do it again. I use to build custom Mini Choppers where I built the frames by hand and used 6 HP go cart motors. They had full suspensions and working HD gas tanks and lights.

Here are 2 that I built.



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