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D.I.Y pannier fitting

RCN

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D.I.Y pannier fitting
« on: July 14, 2017, 12:50:24 PM »
There are top box brackets available for literally all scooters so this needs to be fitted first.

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« Last Edit: July 14, 2017, 12:54:00 PM by RCN »
 

RCN

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Re: D.I.Y pannier fitting
« Reply #1 on: July 14, 2017, 12:57:43 PM »
There are top box brackets available for literally all scooters so this needs to be fitted first.

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This pic shows the under side of the existing bracket

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RCN

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Re: D.I.Y pannier fitting
« Reply #2 on: July 14, 2017, 01:00:51 PM »
There are top box brackets available for literally all scooters so this needs to be fitted first.

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This pic shows the under side of the existing bracket

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Next you need a short piece of flat bar. I used 1/4 inch thick bar as this is the part that has the most loading on it. I fixed it to the under side of the strongest part of the stock bracket using 4x 6mm stainless bolts.

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RCN

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Re: D.I.Y pannier fitting
« Reply #3 on: July 14, 2017, 01:12:15 PM »
Once fitted there needs to be approx 2" sticking out either side of the topbox platform like this with 2x 10mm holes drilled
 

RCN

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Re: D.I.Y pannier fitting
« Reply #4 on: July 14, 2017, 01:22:41 PM »
The Next thing you need is two more pieces of flat bar with 90 degree bends in them. I used oxy acetylene gear to heat mine up so the there was less stress on the metal.
The top sections need 2 10mm holes also to match up with the other bracket.
Obviously the measuring part will need to be "bike-specific" and also depending on how far back you want the boxes positioned. Once the two side parts are made then you can line these up with your boxes and drill them to suit what ever boxes you have.


 

RCN

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Re: D.I.Y pannier fitting
« Reply #5 on: July 14, 2017, 03:15:41 PM »
This picture clearly shows the attached side brackets.
When I have more time and have a proper workbench set up with bench grinder I will re-size the side brackets and spray grey to match the rest.


I also made this part for additional bracing but once it was fitted it didnt offer enough extra rigidity to justify the extra weight.

This is the finished setup for now.
Once I have the time I will sort the side brackets and wire signal and brake lights into the boxes.


I also made the cushion myself from some scrap materials I have kicking around :)


HOPE THIS HELPS SOMEONE AT SOME POINT :)
Any questions please just ask
 

CROSSBOLT

Re: D.I.Y pannier fitting
« Reply #6 on: July 15, 2017, 06:52:32 AM »
Pretty neat and simple adaptation. Good pictures!

Karl
 

RCN

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Re: D.I.Y pannier fitting
« Reply #7 on: July 15, 2017, 05:12:29 PM »
It started off being a lot more complex and heavier but after looking at it in action I could see areas of improvement both in looks and dynamics
 

Re: D.I.Y pannier fitting
« Reply #8 on: July 17, 2017, 07:01:51 AM »
It sure looks good from here!  :)
 

RCN

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Re: D.I.Y pannier fitting
« Reply #9 on: July 17, 2017, 06:24:23 PM »
Thanks Mr Paul,
Its amazing what you can do with a bit of imagination and constant "tweeking" haha.
I just cant leave things alone if I can see improvements which can be made.