How to Make a Bicycle Saddle Bag

IncaPower

Editor

posted on 10 years ago — updated on 1 second ago

35
views

Saddlebags or panniers are an awesome add-on to your bicycle. Not only do they look aesthetically good but they are very functional as well! However, saddlebags can be a bit expensive or some available on the market just won't suit your taste. Why not make your own saddlebags? It's not hard as you think and as long as you have all the materials needed, it will take perhaps just a day or less to make. Follow these steps and let's get started.

Steps

Single Saddle Bag

Find a suitable bag. It's better if you can find something that is weatherproof for durability, but any bag you have will do in a pinch. Get a bag with that retro-appeal or euro-look. You could go an old army bag from a military surplus store.Make a Bicycle Saddle Bag Step 1Bullet1 Version 3.jpg Visit the nearest thrift shop in town. There are no limits here in what style you want. You can even go for canvas grocery bags.Make a Bicycle Saddle Bag Step 1Bullet2 Version 3.jpg

Measure the size of your bag. Make sure to measure the length and width of the bag, as well as the base of the bag. Transfer these measurements to a 1/4-inch plywood.Make a Bicycle Saddle Bag Step 2Bullet1 Version 3.jpg Cut the wood to the size of your bag.Make a Bicycle Saddle Bag Step 2Bullet2 Version 3.jpg You should now have two wood panels, one for the back of the bag and the other for the bottom of the bag.Make a Bicycle Saddle Bag Step 2Bullet3 Version 2.jpg

Obtain two L-brackets Attach the back and bottom of the saddlebag using the L-brackets.Make a Bicycle Saddle Bag Step 3Bullet1 Version 3.jpg Add wood glue for more strength and allow to dry. You now have a board for your saddlebag.Make a Bicycle Saddle Bag Step 3Bullet2 Version 3.jpg

Tuck the board inside the bag.

Find something sharp (like a scissor or ice pick) and poke the corners. The holes should be at least 1 to 1.5 inches (2.5 to 3.8 cm) away from the corners. Get a large screwdriver to make the holes bigger.Make a Bicycle Saddle Bag Step 5Bullet1 Version 3.jpg These 4 holes will be use to join the wooden board to your bag.Make a Bicycle Saddle Bag Step 5Bullet2 Version 3.jpg

Obtain two set of U-bolts. They should be about ⁄4 inch (0.6 cm) in size, depending on the size of the frame of your bike. For a test fit, mount the U-bolts on the bike rear rack. Get the measurements of the U-bolt from the rack and apply this to the saddlebag. Poke the holes for the U-bolts.Make a Bicycle Saddle Bag Step 6Bullet1 Version 3.jpg

Remove the board from the bag.

Drill the holes for mounting. Using the markings the board got from the sharp object you used to poke the bag as a guide. You should have 4 holes for you to attach the board to the saddlebag.Make a Bicycle Saddle Bag Step 8Bullet1 Version 3.jpg Drill another set of holes for the U-bolts so you can mount the saddlebag to the bike rear rack.Make a Bicycle Saddle Bag Step 8Bullet2 Version 3.jpg

Insert the wooden board once more. Screw 4 ordinary ¼-20 nuts on to the holes you made accordingly. Screw the nuts on the 4 corners of the bag, securing together the bag and wooden board.Make a Bicycle Saddle Bag Step 9Bullet1 Version 3.jpg

Prepare the rear rack. Get your U-bolt and place them on the rack. It is better you place the saddlebag on you left side of the bike so it won't interfere with any moving part of the bike, like the sprocket. Insert the U-bolt from the bike rack to the fabric of the bag.Make a Bicycle Saddle Bag Step 10Bullet1 Version 3.jpg

Insert the U-bolt to the bag, passing through wooden board.

Secure the saddlebag to the rack by tightening the nut of the U-bolt.

Add a foam board to the bag for insulation, to dampen the cargo and hide the wood frame.

Tuck the bag's straps in and you're ready to go. Cleaning is easy- simply loosen the nuts of the U-bolts. You can even detach the bag and carry it when off your bike.Make a Bicycle Saddle Bag Step 14Bullet1 Version 3.jpg

Now you're done! This saddlebag can carry approximately 4 kilos of cargo.

Looks cool on your bike! Enjoy your own DIY bicycle pannier.

Dual Saddle Bags

Visit your nearest thrift shop and buy two identical bags.

Measure the length and width of both bags.

Transfer these measurements to a piece of plywood. Cut the plywood into size.Make a Bicycle Saddle Bag Step 19Bullet1.jpg

Insert the plywood into the bag.

Install a bike rear rack (this is where you will mount the saddlebags)

Place the bag on the side of the bike rear rack. Visualize where to mount the bags. Mark the areas where you will put holes on the bag where the U-bolts will go through.Make a Bicycle Saddle Bag Step 22Bullet1.jpg