KLE Pannier Racks - DIY

This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.

Justin

Race Dog
Joined
Jun 13, 2006
Messages
808
Reaction score
0
Location
Centurion
Bike
Yamaha XT 660 Z
Hi all
So, I didn't have the cash for new pannier racks. I decided to DIY it.

Tools required:
15mm Pipe bender (bought on junkmail and can bend 15mm and 22mm steel)
2m 15mm steel pipe
2m 10mm steel flat bar
Some spanners
Angle grinder (to cut the steel)
Power drill with good steel drill bits (for the holes)
Some nuts, washers and screws
Can of black matte spray paint
Some 15mm pipe plugs (Comes over the end of a hollow pipe)


The reason I did this was to keep my soft luggage away from the exhaust and body.

So, first I tried to measure the panniers, where the bend must start, where it must end. I think I actually miscalculated the first one, causing a tapered look. However it looked quite good so I did the same with the second panner.

Then I cut the flat bar to length (3 pieces: one for each side and one big one going from pannier to pannier)

I drilled the holes as required (easy through the pipe, but difficult through the flat bar). Also, I noticed the slower I drill the better the results. I think the steel gets too hot when drilling fast.

Then I fit everything to make sure it all matches, and remove it again.

Spray paint the pieces of metal.

Fit again.

Done!

PS. I will add another flat bar running below the exhaust from one pannier to the other. This will decrease flex of panniers.

Next job: The pipe bender bends 22mm steel pipe easy, and this is exactly the width I require for crash bars.....
 

Attachments

  • 002.jpg
    002.jpg
    167.5 KB · Views: 283
  • 004.jpg
    004.jpg
    89.8 KB · Views: 282
  • 006.jpg
    006.jpg
    59.2 KB · Views: 278
  • 011.jpg
    011.jpg
    97.1 KB · Views: 277
  • 012.jpg
    012.jpg
    42 KB · Views: 276
Top