One Ortlieb Back-Roller Classic pannier is 20L. These panniers are approximately 60L each.
It's not my design. Thank Ken. He created the template, and provided the instruction and materials from which my yellow panniers were made. With those, the seams were heat welded - 100% waterproof. The panniers here are sewn, and the seams waterproofed with silicone.
 |
| Front are Ortlieb Back-Roller Classic. The rear: Ken panniers |
The pattern has minimal seams, and therefor minimal sewing. The basic shape is a rectangle with one corner cut out. The corner cut out provides heel clearance. If the size is scaled down, this might not be a problem.
Order of operations:
- Test fabric seam sewing to determine seam allowance required.
- Measure out the template with seam allowances.
- Fold and cut the fabric.
- From the outside side, fold top edge to the inside and hem.
- Sew inside sleeve in.
- Turn inside out and sew the side seam.
- Sew in the bottom.
- Turn right side out and sew buckles on top edge.
- Insert the plastic reinforcener and mark hanger holes for your rack. Check forward-backward for heel clearance.
- Drill and bolt on the hangers.
- Bask in the glow of finished panniers.
The template
 |
The triangle cut out is about 380mm tall and 110mm across the base.
Don't forget the seam allowance around the edge. It will vary depending on the fabric and seam type. I used 30mm for a thick canvas (the green material), but 20mm for thinner fabric (beige material).
Fold the fabric in half. Template straight edge goes on the fold. Mark and cut out.
 |
Plastic Sleeve
A plastic reinforcener will be held in place by this sleeve. It is to stiffen the pannier and give it its shape.
The plastic insert is 3mm plastic. It's 250mm long at the base. 340mm wide at the top, 340mm tall.
The sleeve is sewn inside the where the pannier will lean against the rack. Make the sleeve material the same size as the insert plus a seam allowance.
Remember the panniers are left and right sided. Sew the sleeve on the correct side of the material.
Base
The base is approximately 300mm x 250 mm including seams. Round the corners. It's worthwhile to check the size of the base against the pannier before cutting it out.
Hangers
Mine are 3mm aluminum flat bar bent into hooks. I used 6 x 30mm hot dipped galvanized bolts with a large washer on the inside. 5mm bolts would have been sufficient.
Use a large washer on the inside.
The bolts go through the sleeve, through the plastic reinforcener, the pannier, then the hanger. I left the bolts long. By sizing the hook length, the bolts protrude and stop the pannier jumping off the rack. Else, attach a elastic loop lower down from the hangers to hook on the rack.
 |
| Hooks closeup |
 |
| Hooks from the side |
Buckle
 |
Completed
 |
DIY Seam Sealer
Mix Bunnings Silicone sealant with Mineral Turps (Turpentine). A ratio of about 1:5 silicone to turps. Thinner is better as it soaks into the fabric and doesn't peel off. Mix well, until the silicone disolves in the turps. It should be fluid, like milk. If it is too thick, add more turps. It will mix - keep stirring. Brush on the seams. It will soak into the fabric. Allow to dry - outside.
