DIY Panniers: Plasti Dip Coating

Recently in a post I pondered whether As Seen on T.V. product Flex Seal, or a cousin, Plasti dip, could be used to assist in Bike Hacks.  Shortly thereafter reader Sean contacted us with a cool hack that does indeed incorporate Plasti dip.  All text and photos below are credited to Sean.

* * * * * * * * * * * * * *

It was suggested I submit a photos and comments of my DIY panniers. Rear from old backpacks and front ones made from scratch. I coated them in Plasti Dip. They are super tough and look very nice.

I am planning on doing a solo loaded tour from the East coast to West coast along the 76 route, hopefully in the spring of 2012. I would like to raise some money while I am at it; I have a charitable cause I would like to fund but I have no idea how to go about that process. My co-volunteers at Charlottesville Community Bikes suggested I could make money for whatever cause I choose.

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.

I was trying to make drysacks but I had no pattern. I ended up with a small breach in the sides when I roll it over.

So I made a hood to cover the entire top of the bag. Said breach has been addressed.

Plasti Dip is very nasty but TOUGH stuff. I use the dip can like paint for the seams and the bottom. I coated the bottom and sides many times and then I sprayed the entire bag with the spray version. It takes about one can of each for the pair of panniers. Please be careful, even when working outside this stuff requires a mask.

Here is the finished product. Tough and waterproof.

Here is the the rear detail of front pannier. I used the election sign to provide a rigid skeleton. The hooks came from a bike rack (it is what I had lying around) The bungee is held on with conduit hanger padded with a bit of inner tube. I used a flat 1/8" x 1" aluminum bar as a huge washer on the inside where the hooks are and another shorter piece where the conduit hangers are.

Here is the rear pannier. I made these first before I got the idea to make front ones from scratch.  This was a matching pair of backpacks (I found a pair at the local SPCA re-store for $5) and cut the straps off. I then just coated them the same with plasti-dip just as I did the front ones.

This next picture shows how rubbery this stuff is when it dries.. I even coated the zippers and they are now pretty much water proof. I will make shower cap style covers for these just to be certain because there could be a breach with the zippers.

Here is the rear detail of the rear pannier. I have JANDD racks which caused me to modify the mounting bungee a little. Same conduit hangers padded with inner tube as the front panniers. Same election sign skeleton with aluminum flat bar washer.

And finally here is the complete set on my TREK 750 I rescued from the trash. The $4 handlebar bag is a typical older one that I found at the same SPCA re-store where I found the backpacks.  I plan to coat with plasti-dip as well so it becomes a little tougher and waterproof-er. The under seat drybag is the only one purchased new and it came waterproof.

Comments

[Chris G]

I've seen Sean's bag work in person. They are nice. I think he could go into business making them.

[Jennifer F.]

I have also seen Sean's bags. They are really tough, and I think they will easily withstand any weather he may encounter on his cross-country trip. I agree with Chris - Sean should sell these!

That's some good work right there!

[Amy E.]

awesome! i've been thinking about making some homemade panniers for my brother who also wants to do a cross-country trip. thanks for the inspiration!

[___Danno]

Wow Those bags look bomb proof. Bravo!

[cycler]

By Election sign, I presume you mean the plastic-"gatorboard" type corrugated stuff? Good idea, and I may try that for my grocery panniers as lightweight structural reinforcement.

[CED COATING IN INDIA]

Ambika Coaters a Leading CED Coating Industries Established In 2011.We Have The Electroplating Unit Name as Ambika Industries This Unit Established in 2004. We Have Fully Automated ED Coating Unit in Bommasandra, Bangalore.

CED COATING
CED COATING IN INDIA
CED COATERS IN INDIA

For More details visit :- http://www.ambikacoaters.com/

[CED COATING]

Ambika Coaters a Leading CED Coating Industries Established In 2011.We Have The Electroplating Unit Name as Ambika Industries This Unit Established in 2004. We Have Fully Automated ED Coating Unit in Bommasandra, Bangalore.