Pannier Racks for Big Boy/Hawk 250

[lilgman]

I'm wanting to put some soft pannier/saddle bags on my Big Boy 250 which is basically the South African version of the Hawk but with a balanced engine. After looking at threads here and pictures all over the web, it looks like pretty much everyone uses tubing for this. I don't have bender, or a way to buy one with the border between Lesotho and South Africa closed, so I decided to try something different. I used some 5mm flat bar I had lying around.

I'd love to hear your thoughts. Will work?it Any obvious improvements?









I was originally planning to put a cross brace from the two sides tight to the fender just out of reach of the knobby. I may still do this, but if I weld it, there's no way to take the rack off. It will have to bolt on as I don't want this to be completely permanent.



Here's a picture of one of the saddle bags. It's still a work in progress--no straps yet. They started life as a high quality tonneau cover for my 25-year-old Toyota Hilux. I have a canopy/cap for it so never used the cover any more. My elderly friend is really good at sewing canvas, shoes, etc., and he needed money to buy food during this Covid thing, so that gave him a couple days of good-paying (for here) work. Once I get the racks all figured out, I'll take the bags back to him to have straps and buckles put on.

[alex_in_az]

Originally Posted by lilgman

I'm wanting to put some soft pannier/saddle bags on my Big Boy 250 which is basically the South African version of the Hawk but with a balanced engine. After looking at threads here and pictures all over the web, it looks like pretty much everyone uses tubing for this. I don't have bender, or a way to buy one with the border between Lesotho and South Africa closed, so I decided to try something different. I used some 5mm flat bar I had lying around.

I'd love to hear your thoughts. Will work?it Any obvious improvements?

Attachment 22173

Attachment 22174

Attachment 22175

Attachment 22176

I was originally planning to put a cross brace from the two sides tight to the fender just out of reach of the knobby. I may still do this, but if I weld it, there's no way to take the rack off. It will have to bolt on as I don't want this to be completely permanent.

Attachment 22177

Here's a picture of one of the saddle bags. It's still a work in progress--no straps yet. They started life as a high quality tonneau cover for my 25-year-old Toyota Hilux. I have a canopy/cap for it so never used the cover any more. My elderly friend is really good at sewing canvas, shoes, etc., and he needed money to buy food during this Covid thing, so that gave him a couple days of good-paying (for here) work. Once I get the racks all figured out, I'll take the bags back to him to have straps and buckles put on.

looks pretty good, I think I'd be inclined to try and put something in at the back lower corners to try and tie them together. if you had a bar low enough, would it be possible to just rotate the rack off using the rear light as the axis of rotation?

[lilgman]

Originally Posted by alex_in_az

looks pretty good, I think I'd be inclined to try and put something in at the back lower corners to try and tie them together. if you had a bar low enough, would it be possible to just rotate the rack off using the rear light as the axis of rotation?

I was hoping that would be possible, but no. I actually tacked a bar on to try it. I agree with you that this cross piece is needed, though. It's going to strengthen it a LOT.

[Goob]

Originally Posted by lilgman

I'm wanting to put some soft pannier/saddle bags on my Big Boy 250 which is basically the South African version of the Hawk but with a balanced engine. After looking at threads here and pictures all over the web, it looks like pretty much everyone uses tubing for this. I don't have bender, or a way to buy one with the border between Lesotho and South Africa closed, so I decided to try something different. I used some 5mm flat bar I had lying around.

I'd love to hear your thoughts. Will work?it Any obvious improvements?

Attachment 22173

Attachment 22174

Attachment 22175

Attachment 22176

I was originally planning to put a cross brace from the two sides tight to the fender just out of reach of the knobby. I may still do this, but if I weld it, there's no way to take the rack off. It will have to bolt on as I don't want this to be completely permanent.

Attachment 22177

Here's a picture of one of the saddle bags. It's still a work in progress--no straps yet. They started life as a high quality tonneau cover for my 25-year-old Toyota Hilux. I have a canopy/cap for it so never used the cover any more. My elderly friend is really good at sewing canvas, shoes, etc., and he needed money to buy food during this Covid thing, so that gave him a couple days of good-paying (for here) work. Once I get the racks all figured out, I'll take the bags back to him to have straps and buckles put on.

You may not have an EMT bender, but you can weld! Looks nice...please re-post once you have the cross-brace figured out. It will make a difference, mainly in keeping the panniers from tilting inward at the bottom. Here is my EMT pipe rack, no bending involved, using makerpipe.com connectors. Been posted before...just thought you would like to see it.

[Megadan]

There is no reason the flat bar shouldn't work just fine. It might flex a bit more than tubing, but that can also be an advantage if you happen to lay the bike over. It might just spring back to shape, and if not, it will be much easier to bend back into shape.

[lilgman]

Originally Posted by Megadan

There is no reason the flat bar shouldn't work just fine. It might flex a bit more than tubing, but that can also be an advantage if you happen to lay the bike over. It might just spring back to shape, and if not, it will be much easier to bend back into shape.

I also noticed that the flat bar is fairly springy. I'm pretty sure tubing would be lighter, but probably not by that much.

And it's now "if I happen to lay the bike over," but when!

Goob, thanks for sharing your pictures. I found them as I was searching for ideas on this. It's great for when you can't weld or don't have a welder! I'll post a picture of the cross piece, but I think it's going to be a while. I've got another project going, too--making new kitchen cabinets. I wish it was a metal job. I seem to do better with a welder and grinder instead of precision wood work! I'm asking the good Lord for patience!

[Megadan]

Originally Posted by lilgman

I seem to do better with a welder and grinder instead of precision wood work! I'm asking the good Lord for patience!

Just remind yourself often that you can always remove more wood, but you can't add it back.

[lilgman]

"Measure twice, cut once."

[f15sim]

Originally Posted by lilgman

"Measure twice, cut once."

Measure with micrometer, mark with chalk, cut with chainsaw.


g.

[lilgman]

Originally Posted by f15sim

Measure with micrometer, mark with chalk, cut with chainsaw.


g.

[alex_in_az]

Originally Posted by f15sim

Measure with micrometer, mark with chalk, cut with chainsaw.


g.

beat to fit, paint to match

[lilgman]

Originally Posted by alex_in_az

beat to fit, paint to match

When in doubt use a hammer. The bigger the doubt, the bigger the hammer!

[lilgman]

I finally got the first installment of the cabinets finished. Now my lovely wife wants a couple more small ones to match on the other side of the kitchen. I started those, too, but got rained out today. Yippee! That gave me some time to work on this saddlebag project again!

First, here's a picture of the cupboards. It was a MAJOR learning experience for me, but turned out fair.



Ok, is picture uploading working today? Let me check.

[lilgman]

I did make a cross piece across the back corners of the rack to strengthen it. It fits just inside the fender.

[lilgman]

Here's the finished (for now) product. I haven't tried it yet to see how it rides.