Here is the complete set panniers I made for my touring bicycle. I simply expanded on existing ideas I found on Instructables and other sites concerning the fabrication of homemade panniers.

Step 1:

I had already started coating the bags. The material is a polyester canvas. I welded the seems together with a flat tipped soldering iron and put zig-zag stitches to add strength.  I just cut a long piece of material and made a squared U out of it. I then used two rectangle pieces for the sides and good old velcro for the closures.
Clear silicon sealant thinned with turpentine is quite useful for sealing material too. Mix silicon with turps at about 1:3 and paint it on. I have fixed old backpacks with PU backing. When the PU deteriorates a couple of coats of silicon and turps and its all good again.
I was initially going to waterproof the rear ones with the homemade waterproofing stuff but they backpacks I got were REALLY thin material. The plastidip pretty much made them bioproof.
i like it
Coroplast - Also known as coreflute. Real estate signs are also a good source for this stuff.
Hey, any idea what size or brand the bags you used were? Am looking to do exactly what you did, and your bags look amazing, but I can't tell what size they are or where you'd get them!
I found the backpacks as a pair at the SPCA restore in Charlottesville, Va. The tag on the inside says OWL. I looked the company up and they seem to specialize in making fabric from recycled water bottles. I think I paid $4 or $5 for the pair. I do not know the size- you can get an idea from the photo of them on the bike. I wanted smaller panniers so I looked for smaller bags. I would have preferred them a little smaller but these are what popped up as a pair at the restore so that is what I used. The front ones are scratch made.
Wow, these are lovely (and look quite durable!) You might be interested in the ikea briefcase panniers instructable I just shared. http://www.instructables.com/id/20-Ikea-Briefcase-Bike-Panniers/ <br> <br>(Probably best for commuting - so not nearly as awesome as these for touring.) Anyhow - lovely instructable, thanks for sharing it!
I'm glad my bike made a background shot!
This is really great. Thank you for posting this. I definitely am going to try making my own version.

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