Instructables
I am an avid commuter and I wanted to add panniers to my bike, but with a twist. I was inspired by the use of the ammo box for the cover of "Final Doom", and Zapwizards computer mod. I had a few of those ammo boxes lying around, and I figured they would make great panniers.
 
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Step 1: Gather Materials

I did this on a whim, so I did not plan very well, or buy the best supplies.

There was only one place to get stainless hardware in my small college town, so I had to make do with what I had.

I bought some stainless machine screws(needed bolts), nylock nuts, and 1/2" clamps.

I had an old inner tube lying around to use in the clamps to prevent squeaks.

Finally you need the ammo box they are commonly refered to as 25mm ammo box(or can).
They are made of heavy duty plastic, open at both ends, have a rubber gasket, a removable divider for the projectiles, and they should be waterproof.
25mm ammo box

Step 2: Anti squeak

This step became useless when I found out they make clamps with rubber dampeners already installed.

I wasn't into measuring so I just guesstimated with a lighter.

Step 4: Fully mounted

Mount both sides otherwise it will lean one way or the other.

Step 5: Load them up

Plenty of room for a change of clothes and my school books.
Too bad it was way heavy.

Step 6: Try different boxes

I did this for the photo op.
stevenj598666 months ago

you should rig a ammo box to the front end for a counter Waite to keep it from tipping

back

lane291 year ago
How much weight do they add to the bike
Sluttyduck (author)  lane291 year ago
I'm not sure; but a quick google says 12lbs.
When I had them loaded with my books and clothes for the day the bike was very back heavy and would tip back when I wasn't on it.
what kind of rack is that?
Sluttyduck (author)  frisbeechamp19831 year ago
Hello, I haven't checked this in years.
I don't recall what the brand was, I picked it up at a bike shop ages ago. Part of it broke off and I eventually only used it to hold a u lock
rhendric3 years ago
I know the smaller ammo cans are made out of metal, but what are the 25mm ammo cans made out of? Great idea and instructable!
Sluttyduck (author)  rhendric1 year ago
Hello, some sort of plastic/nylon. It's very sturdy and watertight at least until I drilled those holes.
onrust1 year ago
A very tactical looking bike. Looks ready for any mission.
I like that these are low and flat enough to easily swing your leg over. The trouble with many DIY bike cargo carriers is that you have to be a ballet dancer to mount & dismount with the bike loaded up. It's hard to look cool when you are in a heap on the ground, under your bike, with a foot snagged on the milk carton. ;-0
I really like these. There are some lighter ammo & boat boxes on the market. Not as sturdy, but perhaps more practical? I've got commercial panniers, but I think one of these would be a good addition to the home-made dog stroller.
I what to put one on my bike!
thrillticks3 years ago
Great place to find that ammo can is http://www.wholesalearmynavy.com/proddetail.asp?prod=originalmilitarysurplusammocans.
freewheel4 years ago
This is a totally rad idea. See if those motorists give you any hassles now!
Subfightr5 years ago
awe, I should have known people were wize enough to make such a thing, my instructable is useless. You did a wonderful job, looks great. Perhaps just go with smaller ammo cans next time seeing as it was too heavy? Cause it is really useful. I would like to figgure out a way to make it secure yet easily detachable, hidden clamps or something. Anyway, great job! thank you for sharing.
Sluttyduck (author)  Subfightr5 years ago
Share what you have anyway. Even if it's duplicate. I think you can buy replacement mounts for some of the more fancy panniers, and then mount them on ammo boxes. Give it a try and make an instructable.
Palifox5 years ago
Good idea sluttyduck, pity they were heavy. I suggest for commuting - light shopping a pine wood box with sides 6 inches (15cm) high on a plywood base. Style, paint and decorate how you like, fit reflectors at rear, maybe provide mounting for a tail lamp. You can bolt a telescopic pump holder to the front, or a battery carrier for lights, hang a tool box or water bottle from it. Size it to suit a standard briefcase for school or work use. Takes a loaf of bread and a carton of milk with room for a few other items. You can even make a tonneau from vinyl if you wish. These used to be common in the small Aussie town I spent most of my teens in. I made one the other day, but should have made it a little larger.
Fianally, a way to carry around all my ammunition.
SureShot5 years ago
Very cool!! What sort of boxes are the first ones? They seem to look like plastic. Are they?
Sluttyduck (author)  SureShot5 years ago
They are 25mm high explosive rounds ammo boxes(cans whatever).
They are plastic, or possibly some type of nylon, they also have a gasket at each lid. http://www.galaxyarmynavy.com/item-9105.asp According to this site they're 13lbs!
I thought about taking a small grinder or something to grind out the inside to shave some weight(there's a lip in the middle), and they're pretty thick.
Thank for the link.
Sluttyduck (author)  Sluttyduck5 years ago
Oh right, the grinder, after more thinking I decided that would be a huge pain in the arse.
I just made one, going to go back to my local surplus store to get another ammo box. It is a little on the smaller side, so if I see anything in the future that is larger, I might pick it up. But it's good for what I do. It can hold a bag of milk, which is great. Even 6 bottles of beer, which is even more great.
ammo_box_pannier.jpg
Sluttyduck (author)  CrimsonFlash5 years ago
Looks good, post some more pics when you mount another one.
Okay, added another one on the other side. Sorry about the picture quality, it's from my camera phone. They look nice, and work well. Noise is a bit high, but I seemed to quiet it down a bit by adding some sticky foam on the places where it hits the frame, as well as adding two bungie cords on each box to keep it to the frame better. All in all, I really like them. :)
ammo_box_pannier_2.jpgpannier_full_view.jpg
What kinda bike you riding? I've never seen one like that, with the fenders, khaki green paint job and rigid front forks, looks like a good commuter. Also, I once strapped a few small ammo pouches onto my handlebars, which were useful for putting wallet, phone, keys etc. in while riding.
Sluttyduck (author)  I smell bacon5 years ago
2006 Marin Pointe Reyes I love it
gmoon5 years ago
Great usage! I've a couple ammo boxes lying around too; still searching for a project...
Sluttyduck (author)  gmoon5 years ago
Thanks, but it wound up being too heavy to be practical. It was cool for a week though.
Understood--but I still like it...