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My DIY Pannier Racks


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I posted this in another forum I frequent, but because I like sharing images... I made some racks for my soft luggage. Soon the panniers will be bolted to the racks so I don't have to use those stupid velcro straps, and eventually the racks will be quick release and use the original hard luggage mounts.
 
 
 
I got some 1/2" aluminum rod and bent it to the rough shape in a vice. Used a propane torch to help the bends, but it was likely not needed:
 
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Cut off the excess and I was really impressed that the ends lined up. When I was bending, I figured the bend spanned about an inch and just eyeballed it.
 
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Got some 2.5"x0.25" bar and cut it down to 12" for each side. I wish I got 2" instead, but I think the 2.5" will work better for my future plans. Rounded off the corners with a file and drilled some holes.
 
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Got some steel spacers from the hardware store to hold the bracket off the bike. These spacers will double as the hookup points for my elastic cargo net.
 
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Welded it up.
 
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Installed the bags.
 
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oooo....reflective
 
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  • 4 years later...

Looks like I'm late to the party but that looks amazing I was thinking of doing the exact same thing. Not sure if anyone is still monitoring this but do you think the 1/2" is just the right thickness? no thinner, no thicker?

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  • 1 year later...

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