Making your own pannier frame?

**Machiavelli** · 17th December 2008, 17:08

Hey all,

Long time no post. I know panniers don't qualify as things that 'keep the skin on your body', but this is the only gear section I could find.

I have a Suzuki GN250 and, hell, I want to be able to do some real riding with it. Touring - if you will - were touring actually possible on an 8L tank.

Snigger all you like

but I want to fit a set of pannier frames to my GN but I'll be damned if I can find any suitable. The lads at Rolling Thunder said they didn't exist but I DID find some bloke in Germany who sells them specifically for the GN250 so I know its possible (shipping them from Germany is a problem I don't want to worry about at this stage).

I'm getting a GN250 venture rack & bag sent to me (thanks TradeMe), but I'd also like panniers for some serious biker-holiday-action with a possible pillion passenger (again, I know, why on a GN250? The choice is simple when its my only bike!).

Do you know of anyone who sells GN250 pillion frames, anyone who does custom work like that, or how I might be able to do it myself? Bear in mind I have extremely poor technical skill in metal-crafting, err, metallurgy... uh, you get what I mean.

**JMemonic** · 17th December 2008, 17:20

Willing to help build some if you find panniers

**Gremlin** · 17th December 2008, 17:57

It depends what sort of bags/boxes you want to fit to those frames.

I'm going through the process now, and want to fit givi panniers to a bike for which there are no pannier frames. Checked with a shop, they said, yep, we can do that kind of metal work.

Got a sv650 pannier rack (all thats really needed is the plate layout that allows the box to attach) and the mount points will all be custom done.

**Machiavelli** · 17th December 2008, 18:25

Originally Posted by JMemonic

Willing to help build some if you find panniers

That's very generous of you!

I'll have to go do some window shopping for panniers that fit my little bugger (stupid sticking-out indicators!) and get back to you.

There are probably not all that many options of panniers that I will like and that will also be the right size for my GN.

Gremlin, I think probably I will go for leather panniers rather than the fibreglass boxes. Admittedly I have much to learn about weatherproof options, inside volume, and security (it might be nice to lock them but im not sure if leather ones do that or not).

**JMemonic** · 17th December 2008, 18:39

Originally Posted by Machiavelli

That's very generous of you!

I'll have to go do some window shopping for panniers that fit my little bugger (stupid sticking-out indicators!) and get back to you.

Dont let the indicators dictate what you buy, they can be moved.

Originally Posted by Machiavelli

Gremlin, I think probably I will go for leather panniers rather than the fibreglass boxes. Admittedly I have much to learn about weatherproof options, inside volume, and security (it might be nice to lock them but im not sure if leather ones do that or not).

Hard panniers if you can find them, leather looks nice but its water repelling ability's are negligible. Have a look around trademe although the selection is not great, or have a look at the road guide site for ideas.

**Gremlin** · 18th December 2008, 06:39

Originally Posted by Machiavelli

Gremlin, I think probably I will go for leather panniers rather than the fibreglass boxes. Admittedly I have much to learn about weatherproof options, inside volume, and security (it might be nice to lock them but im not sure if leather ones do that or not).

Its more a case of knowing what panniers you want, and how they mount, then building that pannier rack... reverse engineering

Depends what exactly you'll use them for, as givi are the best for lock and go, heavy use, waterproof etc etc. If you just want to put some stuff in them for little trips, only in fine weather etc, what you get can change.

**The Pastor** · 18th December 2008, 09:33

Just get soft panniers or saddle bags mate, - you just have to tie them onto the bike - ez.

As far as water proofing goes - you can buy water proof bags - used for kyaks sailing boats diving etc or just wrap up inside a few large rubbish bags and tape up.

Cheap and works well - just not so flash looking but on a gn250 the luggage would be the least of your problems in the looks department!

Good work on using your gn250 to tour on, respect +1

**imdying** · 18th December 2008, 09:33

Six layers of 6oz carbon and some 2mm coremat, we could make some super racing pannier frames!

**swbarnett** · 18th December 2008, 13:23

Originally Posted by JMemonic

Dont let the indicators dictate what you buy, they can be moved.

Indeed they can. I moved mine to accommodate some Oxford panniers when I had my GN. Take a look at my profile picture. The same panniers that I've got on my CBX were used on the GN.

**Machiavelli** · 18th December 2008, 14:40

Originally Posted by swbarnett

Indeed they can. I moved mine to accommodate some Oxford panniers when I had my GN. Take a look at my profile picture. The same panniers that I've got on my CBX were used on the GN.

Excellent, that is good to hear. Nothing like a little bit of been-there-and-done-that to encourage me along.

I have taken Gremlin's advice to heart and probably decided that a waterproof Givi set would be ultimately better than a set of leathers. I'll save them for my theoretical future cruiser if I get one.
For now, a set of Givi E21's are looking good, waterproof, useful, and small enough to not look weird on my GN.

swbarnett, are those panniers waterproof? Can you get waterproof soft panniers like that?

**swbarnett** · 18th December 2008, 15:45

Originally Posted by Machiavelli

swbarnett, are those panniers waterproof? Can you get waterproof soft panniers like that?

I used these primarily because we had them lying around not being used.

They were surprisingly good in the rain. The odd torrential downpour forced some water through the zips of the outer pockets and a bit seeped in to the main bags but other than that they stayed surprisingly dry inside. They did come with waterproof covers but I never used them.

**Gremlin** · 18th December 2008, 16:07

Originally Posted by Machiavelli

I have taken Gremlin's advice to heart and probably decided that a waterproof Givi set would be ultimately better than a set of leathers. I'll save them for my theoretical future cruiser if I get one.
For now, a set of Givi E21's are looking good, waterproof, useful, and small enough to not look weird on my GN.

wooo someone likes my advice

Funnily enough, I actually just got a set of E21 (N - straight black). You can also get some with studs or something like that, if you fancy that. $249 retail for the pair, seriously cheap compared to the rest of givi, but they aren't quite as strong as the bigger range, with the plastic a little more flexible etc, but as with you, a supermoto would look a little weird carry 46L panniers

**martybabe** · 18th December 2008, 16:31

It can be done my mate, soft panniers don't require much support, leather ones can be dressed ala Harley which will be 90% waterproof.

If your only gonna use the pannier frames for once in a while touring it doesn't really matter what the frames look like as long as they're fairly robust and removable when you get home.

This is gonna sound crap and I have no pictures to prove it but I once fashioned some frames out of freezer compartment racks,cut to shape with a simple hacksaw secured with hose clips. Removable and robust. Yes they looked a bit naff but it was all hidden by the bags, worked really well.

Total cost was about 10 dollars, not including bags, but the point is they worked superbly. Obviously if your gonna have a go the most important thing is that it's all secure on the bike.

Good luck whichever way ya go, I toured for years on an RD250 (till it blew up) great fun, enjoy.

**Motu** · 18th December 2008, 17:21

I've made my own pannier racks before using strap steel.Panniers are made for my bike....but I want something lighter and smaller.So last night I found my old pushbike saddlebag frames,I had used these on motorcycles before.Now I just have to find some nice bags or cases to fit on them.

**Dodgyiti** · 18th December 2008, 19:10

Originally Posted by renegade master

Just get soft panniers or saddle bags mate, - you just have to tie them onto the bike - ez.

As far as water proofing goes - you can buy water proof bags - used for kyaks sailing boats diving etc or just wrap up inside a few large rubbish bags and tape up.

Good work on using your gn250 to tour on, respect +1

i bought soft bags and found waterproof boxs that fit perfectly inside and made them hold their shape from payless plastics, took a bit of looking but the range is huge. now everything is watertight and the bags are like hard luggage when on the bike.

and respect dude, gn250 touring- enjoy the scenery!