Instructables

Motorcycle Panniers made out of plastic Ammo Boxes

Looking at other pannier options, I decided to build my own. I made these in an afternoon and think they turned out great. Welding skills were required. I used existing mounting points. I painted them with WINZER high solids paint. The Ammo boxes cost $10.00 each the steel I had from another project.
 
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Step 1: They are mounted on the bike in this shot.


They where built to hold big bullets so they are water tight.  I would like them to be a little bigger but they are great otherwise.

Step 2:

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I cut the steel and bolted it in place using the mounting points already on the bike.
Then I covered the bike with fire proof cloth and held up the next piece. After tack welding evering in place I took the piece off the bike and did the finish welding.

Step 3:

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I held each part in place and lined it up to be square and true. One goal is to place the racks in a way to get my body parts off when needed. That was easy to want and hard to get.
I did not miter the joints as I should have, as a result I had to fill the ends of the square tubing.
The brace that ties both sides together fit nicely under the license plate.

Step 4: This is what they looked like after welding.

Picture of This is what they looked like after welding.

It was hard to wait for the paint to dry but its the best thing to do. Dry paint dry.

Step 5: Painting

Picture of Painting

The WINZER paint I use is the best you can get in a rattle can.

Step 6: This what the $10.00 plastic ammo boxes look like.

Picture of This what the $10.00 plastic ammo boxes look like.

They are very heavy duty and will hold the bike up in the case of a fall over. The army builds things well, these are water tight.

Step 7:

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This view shows how close I was able to get them to the bike.
The whole project was easy but dose require welding skills.
Go down to your local tool supplier and pick up a wire feed welder today.
dlindahl1 month ago

I know its been two years, but do you have the lengths of each piece? Or anywhere I can find them. I guess the square is 12 inches because the mounting holes on the ammo cans are 11.25 inches apart. Do you know how long each of the "arm" things are?

josh2 years ago
can you build some for my bike?
doc03332 years ago
I'd like to know where you sourced the ammo cans and how you mounted them to the rack.
Beemer007 (author)  doc03332 years ago
I found them at the Medowin Tall Grass Pararie office. It's at highway I-80 and 55 Jouliet, Ill. But I've seen them on the web too.
Beemer007 (author) 2 years ago
This was my first try at posting a project.
Thanks for the comments.
crapflinger2 years ago
the pictures are nice, but you need more instructions.