Merlite modifications - Kawasaki KLR 650 Forum
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post #1 of 3 Old 02-12-2007, 04:49 PM Thread Starter
Join Date: Jan 2007
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Merlite modifications

Has anyone modified the Merlite coolers into panniers. If so what mods did you do? I picked up a set for a swap and want to put them on my KLR. Thanks Jim : :smile:
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post #2 of 3 Old 02-12-2007, 06:29 PM
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post #3 of 3 Old 02-17-2007, 12:26 AM
Join Date: Oct 2006
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I did the mermite thing...mounted them up to a Happy Trails SU rack. They make great bags, hold a ton of crap, but the work involved in converting them is considerable. I followed this thread over on

He guides you through the basics of gutting them of their insulation, etc. I had some good pics over on, but the site appears to be down...again... :roll:

I strayed from his procedure a little bit in that I left that fiberglass (or whatever that material is) seal around the inner edge of the cans intact so that I could keep the rubber seal and keep them water tight. I just peeled the lip of the inner aluminum chamber up over and then the fun of prying it out began...followed by the joy of scraping the styrofoam insulation out...:roll:

So anyway, you will need some sort of rack to mount them to. Then you will need to figure out what position you want them mounted in, drill the holes, etc. Then figure out what to use for mounting bolts. I found a second hand Happy Trails SU rack, which is a great rack, but not cheap when you buy it new. I just used long bolts and wing nuts for awhile, but it was such a process getting the things on and off that I spent some money on a quick release mounting kit made specifically for the SU rack. Now I finally have them in a user-friendly state.

Oh and I painted them with black Rustoleum "hammered finish" paint, which I was very pleased with. It gave the cans a nice look.

Anyway, if .net gets back up and running I will post some pics...if not, I guess I'll have to dig up the originals.

Good luck, and if you have any questions I'll try to answer them. [/i]
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