My Pannier Design

[zerodish]

I've had bags on my bicycle for the past 30 years. Even when I'm not touring I keep them loaded for testing. These generally fail by pulling apart at the seams. So I decided to eliminate the seams and use lap joints. Every thing you see here is irrelevant this is just an exercise in lap joints. The rest of the bags design makes best use of materials I found on tour. If I do another one I will use a Nomex flight suit and the layers will be glued together with one of the spray on rubbers then sewed and sprayed again so it will be one complete piece. This is primarily a computer bag so I didn't want any bolts going through it. I have some plastic that will fastened to the rack and some that will go inside behind the computers. Each one of those straps are rated at 500 pounds and there are no breaks. I was going to fasten the buckles under the lid but then decided to attach them directly to the rack. There is no way I'm going to allow even the possibility of the straps getting into the wheel so there is additional sewing needed. The buckles came off of shopping carts. The plastic piece shown is called a keeper and can be used if you break a buckle. I found the lawn chair material after sewing the straps or I would have put them under the straps. I will use some leather to reinforce the corners and the lid hinge. Also on the new design I will use a slant design on one side to give heel clearance. I know they are ugly prototypes are allowed to be ugly. https://flic.kr/p/2ojzsfm https://flic.kr/p/2ojzt4v

[John Nettles]

I have always wanted to know how to sew REALLY well so I could make custom tents, bags, clothes, rain gear, etc. as I have tons of ideas on how to "improve" stuff.  I wish you the very best on your project!

[zerodish]

Almost done. I am quite happy with the design. For the model two I am going to complete the bags first then add the straps last. This will make them replaceable and allow me to adjust the placement.  https://flic.kr/p/2oxiz5U

[John Nettles]

So how do they secure to the rack?  John

[zerodish]

On normal bags I generally puncture 2 holes at the top and bolt 2 conduit clamps to the rack. This is an anti theft device and prevents the bags from jumping up on a bump. Also I usually add a conduit clamp around the seat stay which prevents the bags from rotating into the spokes. With these bags I am going to tie the bags to the rack. Also shown you would have to remove the flashlight to get the bags off. This is 2 conduit clamps with 2 different types of bolts.

[David W Pratt]

John-
I can't sew, even poorly, but I have gotten some gear made by giving a canvas worker the old (heavy, water absorbent) item and asking them to copy it in modern wonder cloth.  It has saved weight, and made the items easier to pack.

[misterflask]

Those are some nice looking bags.  Very impressive.

I still have my first canvas panniers that I conned my mother into sewing 50 years ago.  Yours are more feature-packed.

What are you carrying under your top tube?  It looks like enough spokes to build three wheels.