My Mermite Pannier setup

[bones]

10-95 gave these to Sqeuaky a while back and I nabbed them from Squeaky yesterday. Thanks a bunch to both of you.

Tonight I started gutting the innards.

Here are threads from ADV I am taking from.

Pilots Penny Tech Panniers (http://www.advrider.com/forums/showthread.php?t=17843) I rode with him when I lived in KC and saw his and another locals setups that were identical. Also saw one low side and they just got scuffed up.

Hondos rebuild thread (http://www.advrider.com/forums/showthread.php?t=167193&page=2&highlight=mermite) is more of an overall rebuild, but has mermites in the works.

Plans are to install a Happy Trails KLR650 SU Rack (http://www.happy-trail.com/)

http://happy-trail.com/images/products/KLR_SU_Install.jpg
and get the mermites bead blasted and powder coated if I can source a deal. Anyone know of a place??

Here are the tools I used to gut them to this point. I have about an hour and a half into this and still need to get the bottom foam removed.
-Drill and 1/2" drill bit
-Sawzall and wood blade (all I had, but it worked great on this thin aluminum)
-Hacksaw blade to cut down the foam
-Hammer
-Prybar(s)
-Pliers/Vice Grips
http://30bones.smugmug.com/photos/139173507-L.jpg

First drill some holes in the bottom. I did the first with just two holes on each side and cutting the can from one side to the other, but it made removing the innards a PITA. Also you need to use the sawzall around the edge to help separate the guts from the foam.
http://30bones.smugmug.com/photos/139173563-L.jpg

On the second I drilled the holes in the corners and made more cuts. Work harder not smarter right?? :rofl:
http://30bones.smugmug.com/photos/139173541-L.jpg

Cuts made
http://30bones.smugmug.com/photos/139173619-L.jpg

Guts removed in <5 minutes
http://30bones.smugmug.com/photos/139173643-L.jpg

This is as far I wanted to go tonight. Need to get the bottom foam out and look into getting them blasted and coated. with the rack and hardware I have $215 into this project so if I can get them coated for a reasonable price I will have a real nice setup and for a bargain of a price.

http://30bones.smugmug.com/photos/139173694-L.jpg

Hope this {expletive removed - Mod.} doesn't contain asbestos?!?!?!
http://30bones.smugmug.com/photos/139173752-L.jpg

[Texian]

Whoa!, those bags are crazy!

Great writeup, cant wait to see the rest!

[bones]

Quote #1 can't bead blast them, but powder coating will be roughly $65/ea. We'll see

[Squeaky]

:clap:

Don't forget to weigh them so I'll know exactly what the weight savings would have been vs. my ammo cans.

[bones]

I will see what I can do. Going to gut the lids tonight if I feel up to it and let the sand blaster take care of the rest. They are rather large. :lol:

[dbdolan]

You going to have your KLR back together for the pie run?

[bones]

I am putting it back together tonight or tomorrow. Depends on how motivated I get. Takes all of an hour or so.

Going to walmart and might get some truck bed in the rattle can and shoot the plastics while they are off and can dry for a couple days

[dbdolan]

I am putting it back together tonight or tomorrow. Depends on how motivated I get. Takes all of an hour or so.

Going to walmart and might get some truck bed in the rattle can and shoot the plastics while they are off and can dry for a couple days
If you get the bed liner paint get some 120 grit sand paper and really rough the plastics up then clean with alcohol,then do a few light coats. My first attempt at this around December did not last to long due to my ADD.:lol2: It peeled right off after a few rides but this time I scraped it all off and reapplied it with fewer coats and it seems to holding up much nicer....so far.

[Squeaky]

If you get the bed liner paint get some 120 grit sand paper and really rough the plastics up then clean with alcohol,then do a few light coats.

After you scuff it up, try some Bulldog adhesion promoter. It etches the plastic so the paint will bond more easily, and you can find it @ AutoZone, etc. in the paint section.

[bones]

Wal Marts here SUCK! Wasn't that place invented in this country, err I mean state? :lol:

I have yet to find it here. Should have bought some before moving, it's in every store there. I will get some some other day, bike is back together now so it will have to wait.

[dbdolan]

Wal Marts here SUCK! Wasn't that place invented in this country, err I mean state? :lol:

I have yet to find it here. Should have bought some before moving, it's in every store there. I will get some some other day, bike is back together now so it will have to wait.
I have been using the dupli color bed liner flat black paint from autozone, get at least 2 cans.

[Big Bandit]

If you are going to bedliner the bodywork on the bike.... Why not bedliner the mermite cans. Get an angle grinder with a wire brush and clean the outside, which would also rough it up and spray on bedliner. Of course that does not solve the problem of getting the remaining foam out. You could probably clean it out with the same grinder/wire brush, but I would use a very good respirator and do it outside. As you pointed out, you do not know what is in that foam.

[bones]

That bedliner is not that great IMO. I used it years back and it's hit and miss. I just hate the red plastics is all. I want the boxes powder coated since they will get beat up a lot by gravel, etc.

[Big Bandit]

I have never tried the spray on bedliner. However, I did put a roll on bedliner in my truck and I have been pretty happy with it. I have managed to scrape it off in a couple of places but it is pretty tough stuff. I was dragging a 55 chevy rear axle out of the bed when I scraped a little off. I used Herculiner, you can buy it at Autozone. One gallon with all the application tools is $100 and is enough to do a short bed. You can also buy a quart with no tolos for another $35. I bought two of the $100 kits and laid it down pretty thick in my long bed truck. I have been happy with it. You could buy the $100 kit and do all your body work and cans with a couple of coats and probably have material left over for touch ups.

[Squeaky]

I just hate the red plastics is all.

Then instead of bedliner, go with regular paint. We'll talk on Saturday and/or Monday about the options.

[bones]

wish they sold aftermarket plastics for these. with a bike out for 20 years, NOBODY makes them.:doh:

I am not to worried about the red. I have other things in life to worry about. It's time to ride, maybe over the winter I will paint them...crap! Thought I was still up north, no stinkin' winters here! :rofl:

[Squeaky]

Yeah... get ready for 7 months of summer!

[dbdolan]

wish they sold aftermarket plastics for these. with a bike out for 20 years, NOBODY makes them.:doh:

I am not to worried about the red. I have other things in life to worry about. It's time to ride, maybe over the winter I will paint them...crap! Thought I was still up north, no stinkin' winters here! :rofl:
I got the aftermarket KTM fender for 26 bucks and the tusk hand guards which are both black, 2 less things I had to paint to black out the bike. I am hoping the guy that buys the KLR's to convert for military use will put up some black plastics on ebay from the 2007's like he has been for the red plastic, it is my only hope if the spray paint doesn't hold up.

[bones]

Yeah... get ready for 7 months of summer!
Just seven?

[bones]

I got the aftermarket KTM fender for 26 bucks and the tusk hand guards which are both black, 2 less things I had to paint to black out the bike. I am hoping the guy that buys the KLR's to convert for military use will put up some black plastics on ebay from the 2007's like he has been for the red plastic, it is my only hope if the spray paint doesn't hold up.
Yeah I have had the motard front fender and Acerbis guards since the 3rd week I owned the bike I think. Least of my worries, but my biggest gripe of the entire bike is the color. And to think I used to hate the green. I am just to ard to please in that respect.

[bones]

I used the power washer on the guts tonight and cleaned them out pretty well in about 30 minutes.

[bones]

I mounted them up tonight. Still need a spacer to get the bottom poly bracket to fit right.

All in all I doubt I will like these. They are real flimsy feeling gutted and the lids/latches really are a PITA. I imagine once I get the lid sealed these will only be temporary until I can get some aluminum cases from a vendor.

Pics
http://30bones.smugmug.com/photos/142536656-L.jpg

http://30bones.smugmug.com/photos/142536711-L.jpg

[Tourmeister]

All in all I doubt I will like these. They are real flimsy feeling gutted and the lids/latches really are a PITA. I imagine once I get the lid sealed these will only be temporary until I can get some aluminum cases from a vendor.

All true... but they look gnarly! :lol2:

[kurt]

I've never read anything bad about the $300 KLR aluminum cases.

[bones]

All true... but they look gnarly! :lol2:
Thank god good looks and KLR are not synonymous. My bike gets uglier with every mod IMO.

[Tourmeister]

I've never read anything bad about the $300 KLR aluminum cases.

What cases are these? :scratch:

[bones]

I assumed Happy Trails

[bones]

1x1 Alum angle riveted to the sides
http://30bones.smugmug.com/photos/144053747-L.jpg

Seal glued in place, hope it holds.
http://30bones.smugmug.com/photos/144053911-L.jpg

Couple Old Navy clearance bags to use to bring my work clothes and lunch in, etc.
http://30bones.smugmug.com/photos/144053852-L.jpg

Decided to paint the plastics while I was at it. Spray on bedliner. I will do the mermites once I take them off.
http://30bones.smugmug.com/photos/144054135-L.jpg

[Squeaky]

Will it be back together and rolling to show off tomorrow night @ DS?

[10-95]

What cases are these? :scratch:

http://www.klr650.com/AluminumBoxes.htm

http://www.klr650.com/images/Boxes1Large.jpg

[DFW_Warrior]

Wow, those are some unusual looking bags.... You might want to check Ebay for some pelican cases. They're cheap, lite, and durable.

[bones]

Will it be back together and rolling to show off tomorrow night @ DS?
Rode it in this morning :D Missing the side plastics, but they have not been on for a couple weeks. Rear fender will still be red as I painted a spare I had.

Wow, those are some unusual looking bags.... You might want to check Ebay for some pelican cases. They're cheap, lite, and durable.
The bags are as my girlfriend calls my "murse" :lol2: Fit perfect in the mermites also. I have not ran across any free pelican 1550's so these fit the bill/budget. Plus I am not sold on how the pelican's open

[Moose]

Unless you are real stuck on alu cases - I hear good things about the set-up sold by Caribou Cases ( rack and pelican cases for panniers) supposed to be real tuff

[bones]

Unless you are real stuck on alu cases - I hear good things about the set-up sold by Caribou Cases ( rack and pelican cases for panniers) supposed to be real tuff
If I wanted to drop the coin, those would be on my bike along with the top box. Quick release, locakable to the rack and the case itself. Real nice setup. Just have a hard time dropping ~$1100 on a bike worth maaaaaybe 3 grand.

[kurt]

If I wanted to drop the coin, those would be on my bike along with the top box. Quick release, locakable to the rack and the case itself. Real nice setup. Just have a hard time dropping ~$1100 on a bike worth maaaaaybe 3 grand.

I bought Pelican cases online and mounted them myself on a SWMotech rack on the V-Strom for less than $400 including the rack.

http://img.photobucket.com/albums/v609/kurt1305/Bikes/IMG_0839.jpg


http://www.all-pelican-cases-4-less.com/detail_pelican_1450.html

[bones]

I like that setup also. Real clean!

So far this is my investment:
Happy Trails rack and mount set (slightly used) $215 shipped
Mermites $free
Aluminum angle ~$8.50
2 cans of rattle can bed liner ~$16 (Will need 2 more since I used 1.5 on the plastics :lol:
~4 hours of my time at most $free

So for under $250, I really can't complain.

[kurt]

You mentioned liking the Caribou case setup. You're only about $170 away if you can live without the built in locks (Pelicans can use external pad locks) and can use a drill. ;-)

[bones]

I will roll with this and see how I like having panniers. I imagine if I start going long distances regularly I will get either a second bike for that or sell the KLR and get a touring model. Only reasons I can't do that now is the KLR is so cheap to maintain and easy to work on I can't part with it. Plus I don't have the cash to put towards something nicer and I refuse to finance a bike.