This DIY project will walk through the steps of installing locks onto the hasp/latch of some Touratech Zega Panniers that were originally mounted in a BMW motorcycle. The Zega panniers are the original model that were superseded by the Touratech Zega Mongo and Pro models.

Supplies

Miniature Tubular Cam Lock 3/8" Mini Small Lock Item2200AS Keyed Alike - https://a.co/d/9DxSqwU

Pannier with hasp style lock (models are Touratech Zega

Classic panniers, 45 liter)

Drill with drill bits

Dremel with metal cutting bit and wire brush

Permanent marker to mark edge

Punch tool and hammer

Wood block for support during lock removal and installation

Adjustable wrench

Locktite Blue

Washers to serve as spacers ( I used M12 washers)

Vice for bending lock arm, as needed

Step 1: Remove Old Lock

First step is to remove the old locking me mechanism, as needed. If your pannier does not have a manual lock, please move to the next step.

1. On the Touratech Zega pannier has, place the pannier in a position where you can rest the hasp flat against the wood block. In this example, I placed the pannier on some saw horses with a piece of cement board ad used a 4” x 4” block along with at 2” x 4” block to create a level surface

2. With the hasp flat against the blocks, drill out the rivets using a drill and appropriate bit size. I used 3/16” drill bits to drill out the rivets.

3. Used a punch and a hammer to knock out the rivets and remove the old lock

Step 2: Mark Hole and Cut to Fit Lock

1. Place the new lock in the existing hole and trace an outline using a permanent marker. Position the lock so that it can open and close correctly

2. Wear safety glasses and gloves to protect your eyes and hold the hasp when it gets hot during the cutting process.

3. Use a Dremel with a cutting bit to carve out the hole.

4. Test fit the lock to ensure the hole is the right size

5. Use a wire brush attachment on the Dremel to remove rough edges and marks made during the cutting process

Step 3: Fit and Mount Lock

1. Insert the lock into the hole to verify the distance the lock latch arm sits in relation to the hasp lock bracket. For the Zega Classic hasp and the 3/8” cam lock, I needed to use qty. 2 metric 12 washers to create a lock arm height lock.

2. Mount the lock arm onto the lock to determine the approximate angle to add to the lock arm assembly. Based on measurements from the original locks on my Touratech Zega Classic panniers, I needed to bend the arm to about 30 degrees

3. Mount the lock to hasp using the barrel nut and use Locktite on the nut

4. Mount the lock arm into a vice and use a hammer to set the angle for the tip of the lock arm

5. Mount the lock arm onto the lock, verify the lock arm makes appropriate contact with the lock surface and verify the lock operates correctly