801 side-pannier-rack

[Tom]

Some pics of how a small and simple 401 pannier rack can be adapted (with a custom made bracket and some custom made spacers) to the 801 to attach a small pannier; it's again still work in progress...

 

[CRK]

As always, great craftmanship. Stoked to see the finished product!

 

[blue_monkey]

Super work , Tom!

 

[Tom]

Black coated bracket and spacers.

I've made a simple drawing of the bracket and have scanned it; if anybody also wants to give it a try, send me a pm with your mailaddress and I will send you the pdf.

 

[Tom]

Final assembly...

 

[blue_monkey]

Will the same design work for the other side, @Tom ? Or does the exhaust get in the way? Would be useful to have a bracket that protected soft luggage from the exhaust heat.

 

[Tom]

Will the same design work for the other side, @Tom ? Or does the exhaust get in the way? Would be useful to have a bracket that protected soft luggage from the exhaust heat.

I didn't check the exhaust side; I just want the single side pannier to fit my rain-gear if needed.
According to the photos the space between the frame and the stock exhaust is tight but might be sufficient, but the bracket will be quite long and might be too flexible.
But with some proper luggage the exhaust should be no problem at all.

 

[aphrodisierend]

As always, great work, Tom!

Is this an original 401 side-bag? Looks like the passenger footrests can stay (compared to the original 801 bag), is this right?

 

[Tom]

As always, great work, Tom!

Is this an original 401 side-bag? Looks like the passenger footrests can stay (compared to the original 801 bag), is this right?

Thanks!

It's an aftermarket 401 rack and an aftermarket (universal) side-bag.
They are both quite affordable and can be purchased from Aliexpress, Amazon, Ebay, ...
If you're interested, I can send you the links to the parts I ordered.
I've not tested it with the passenger footrests; but I would also assume it should work.

 

[Tom]

Another pic...

 

[Rossman]

Some pics of how a small and simple 401 pannier rack can be adapted (with a custom made bracket and some custom made spacers) to the 801 to attach a small pannier; it's again still work in progress...

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Hello Tom my name is Stephen Ross and I'm in San Diego California. I been racking my brain trying to find storage besides my tank bag while I'm riding a passenger and losing rear foot peg is a terrible design. My email is Sjrtraumarn@gmail.com. I would love to buy bracket from you if possible and then a left side panier bag medium size. Your my only hope. Please help me Tom. I am. Ot a fabricator or have the necessary tools to make but I could do the install. Thank you so much and peace across the pond. Sincerely, Stephen Ross.

 

[Tom]

Hi Stephen! sorry, but I don't fabricate any parts to sell them; and it also definitely makes no sense to cut, bore and bent a sheet of 5mm aluminum or steel here in Europe to send it over the pond. But I will send you the simple drawing to fabricate the bracket; and I'm sure you can find someone locally who can make it for you; it's not rocket science

Here the links to the 401 pannier-rack and the bag that I ordered.

https://aliexpress.com/item/1005006190403212.html

https://aliexpress.com/item/1005007613504636.html

 

[toast449]

I do FEA for mechanical drawings occasionally and I really don't like how much torque that puts on the aluminum around those two bolts. I get that the stock mount also only uses two but that seems like a failure waiting to happen. I think I saw you are an ME so I imagine you have done some analysis and are okay with it.

I ordered a leather saddlebag/courier bag from Trip Machine in India and will be fabricating something like this but I'm going to weld in some bracing to prevent the whole thing from just ringing like a spring.

 

[Tom]

In real life I'm indeed Engineer/Architect; no I did no analysis; but I did a lot of metal work in the past 30+ years; and my "gut feeling" says it's absolutely fine with the small pannier to carry some rain gear.

Edit:
I was just on the website of "Trip Machine"; nice classic bags; but it seems most of them are much bigger and also much heavier then the tiny leightweight 6 liter bag that I've attached to the rack.
With more weight added to the rack or with a bigger rack, I would also prefer a more stable solution.
@toast449 which bag did you order?

 

[toast449]

Outlaw saddlebag

 

[Tom]

Outlaw saddlebag

OK, that bag is on another level; it's huge compared to the tiny pannier I have attached... agree, a more stable rack will definitely be helpful.

 

[tooth_dr]

Hi @Tom Do you know off the top of your head what thickness of amalgam you use for this? 2mm?

 

[Tom]

Hi @Tom Do you know off the top of your head what thickness of amalgam you use for this? 2mm?

4-5mm Aluminum is fine to fabricate the bracket; 2mm is too flimsy.

 

[tooth_dr]

5mm Aluminum is fine to fabricate the bracket; 2mm is too flimsy.

Thanks Tom. Did you heat yours when bending it? You look to have a very tight internal corner from the first photo.

 

[Tom]

Thanks Tom. Did you heat yours when bending it? You look to have a very tight internal corner from the first photo.

I did it with a vice and some tools at the workbench, but without heat.
On the pics the bracket is made from 3mm aluminum; it works fine with the lightweight rain gear in the pannier, but for some a tad heavier stuff I would use 4-5mm aluminum instead.