Building fiberglass adventure bike pannier boxes

Being a fan of hard luggage I decided to try something a little different and build some fiberglass pannier boxes. Rather than just build one-offs, the plan was to spend a little extra time building moulds so that boxes could be quickly and easily produced. Below is a photo of the finished product on a DRZ400 then followed by how I went about the process:

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Starting with the pannier box lid

First up I’ll go through the steps to complete the pannier box lid plug which creates the pannier box lid mould

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Next is the pannier box

The actual pannier box itself is slightly more complex as it needs to be a two part split mould to accommodate for the wet edge.

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Laying up the final parts in the pannier box moulds

Now that the pannier box mould halves and the pannier box lid mould are complete and cleaned, it is time to start laying up the final parts

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DRZ400 pannier racks and top rack

Click here for an article on the DRZ400 pannier racks and top rack in the above images

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