Motorcycle Panniers Made Out of Plastic Ammo Boxes

Introduction: 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.

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:

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:

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.

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

Step 5: 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.

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:

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.

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    9 years ago on Introduction

    This was my first try at posting a project.
    Thanks for the comments.

    Yard Sale Dale
    Yard Sale Dale

    Reply 1 year ago

    That’s really nice work. Good job.


    Reply 3 years ago

    - Nice project. You might consider (all these years later :o) to make a 'spacer' (say 4 inches - or as you need) - to place in between the upper and lower pieces to make them as wide as you like. - update?


    6 years ago on Introduction

    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?


    9 years ago on Step 7

    I'd like to know where you sourced the ammo cans and how you mounted them to the rack.


    Reply 9 years ago on Step 7

    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.