DIY hard case panniers (lots of pictures) - Kawasaki Versys Forum
 
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post #1 of 9 (permalink) Old 03-13-2014, 03:25 PM Thread Starter
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DIY hard case panniers (lots of pictures)

So I just did not have the money to spend on buying the really nice Kawasaki cases or really any other side cases. I set out to build some for around $100 and this is what I came up with.

Start with all the parts, found the cases at a local army surplus store. I had gone in for ammo boxes but found these night vision cases. They are lighter, waterproof and I can lock them. Found the rest of the parts at Lowes.



Mounted this bracket I found in the build your own fence gate area bolt is a M8 1.25 and 1.5" I think.



Drilled a couple holes in the side to match the bracket then used a rubber washer on both sides with a normal washer on the inside as well as used bolt that are much harder to get off from the outside. Ignore the chain I ended up not using it.



Used a U-bolt on the back to attach it to the frame again. Don't make my mistake on the first one. Make sure the U-bolt is tilted at the same angle as the frame. Again rubber washers, normal washers and nuts used on the inside.



For support on the bottom I had it sit on the passenger pegs, so this won't work if you 2-up but my wife doesn't like the long trips anyways.



Cut the bolts down on the inside and throw some locks on it then call it a day.







I did buy a magnetic tank bag off craigslist for $40 as well.




I used some gun lube to go over the rubber seals on the inside of the cases to freshen them up a bit and help them out in the long run.

The chain did not work out because I couldn't get it to glue on the inside very well and I did not want to drill more holes. I ended up using the super sticky velcro and that seems work pretty well.

Testing it out this weekend on a road trip.
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post #2 of 9 (permalink) Old 03-13-2014, 03:53 PM
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Nice job. Great size and shape cases - much better than ammo cans. I like the position on the bike and the way you used the passenger foot pegs.

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post #3 of 9 (permalink) Old 03-13-2014, 04:40 PM Thread Starter
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Nice job. Great size and shape cases - much better than ammo cans. I like the position on the bike and the way you used the passenger foot pegs.
Thanks, im pretty happy with how they turned out and they feel really solid. We will see after the trip how well they hold up.
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post #4 of 9 (permalink) Old 03-13-2014, 05:10 PM
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Looks like a great solution. Well done.

The cases look nice and close to the bike.
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post #5 of 9 (permalink) Old 03-13-2014, 06:35 PM Thread Starter
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Looks like a great solution. Well done.

The cases look nice and close to the bike.
They are about as close as I could get. I forgot to mention that I put little rubber deals inbetween the case and some plastics near the top where it touches.
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post #6 of 9 (permalink) Old 03-14-2014, 07:56 AM
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You owned a KLR didnt' you?

That really is nice work and the fact that it was only $100 is pretty stunning.

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post #7 of 9 (permalink) Old 03-14-2014, 11:28 AM Thread Starter
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You owned a KLR didnt' you?

That really is nice work and the fact that it was only $100 is pretty stunning.
haha No I never did but I was very close to buying one instead of the Versys.

Thanks, I was pretty happy with the price and it was pretty easy, i'm no genius and I don't have a lot of tools so really anyone could do it.
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post #8 of 9 (permalink) Old 03-14-2014, 12:21 PM
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I too am VERY impressed - NICE job!

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post #9 of 9 (permalink) Old 03-14-2014, 01:24 PM
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That looks awesome. I may try something similar, but I cannot obstruct the passenger pegs as those will be needed from time to time. I was thinking of buying the mounting bracket for hard cases and working off those, but What you did looks much nicer and tighter to the bike.

- Ian Thomas
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