Plywood Panniers - How To

[yycyak]

BLUF: Here's how to make some hard panniers for $28 and a couple hours of your time

***

I'd like to say this post was inspired by two books: Townsend Whelen's “On your Own in the Wilderness” and Joe Back's “Horses, Hitches, and Rocky Trails.” And it sort of was.

But mostly it was this:

I'm up in Canada, so the USD$ conversion sucks. So for guys who maybe can't spend that kind of money, below is a functional alternative that costs a whopping $28 Canada-Bucks per box. The design draws from those two books mentioned above, and also from a set of DIY salt panniers I've seen used in action by an old cowboy.

Difficult level: Easy. It took longer to write and format this post than it did to build the boxes.

SHOPPING LIST
– 2x10x8, x2
– 2x4x8, x2
– 4x8ft ⅜ plywood sheet
– Gate hinges, 2-4”, x8
– Rope, ⅝ or whatever, @ 25ft +
– Old ratchet strap or nylon webbing @ 40”, x4
– D-rings, 1”, x8
– Glue
– Wood screws (½, ¾, 1 ¹/², and 3”)

CUT LIST
– 2x10 @ 17 ⅝”, x2
– 2x4 @ 19”, x2
– ⅜ plywood @ 22x17 ⅝”, x2
– ⅜ plywood @ 22x10, x1
– D-rings, 2x
– Nylon strap, cut @ 40"
– Rope, cut @ 6ft

This list gives you enough lumber to build 2x sets of 2 panniers, or 4 boxes in total. Hardware and consumable stuff is your call on what you want to use, but this had me covered.

Tools Needed
– skilsaw
– measuring tape
– square
– screw gun
– drill

***

Okay on to the build.

Step 1
Cut your lumber using the cut list above.

Step 2
Write “top” at the top of your 2x10 blocks. Now you know where Top is.

Measure down 6 ¾” from the top, along the left side of the block. Make a mark.

At the bottom, measure 7” from the right side of block. Make a mark.

Draw a line between your two marks. Use your skilsaw to cut that line. (May need to fight your blade guard here to make this cut - angle is a bit of a fight.)

Step 3
Glue and screw your 2x 2x4's to the bottom of your cut 2x10's

Step 4
Glue and screw one of your 22x18” ⅜ panels to the back of the frame you just made.

Step 5
Get your second 22x18” panel. Measuring down from the top, make a mark at 6 ¾. Carry this line across the face of the panel.

Set your blade depth to a fat 1/16 of an inch

and scribe (cut) your line. You are removing a bit of material here to make the “bend” in the front face of the pannier a bit easier.


Step 6
Glue and screw the panel you just scribed to the front of the frame.

**Note: your panel might crack along the line. Oh well. Plywood sucks these days. If it does, just keep going.

Step 7
Take your 22x10” panel, and put it on top. Add your hinges. Use your ½” screws on top, and longer screws for going into the 2x10

Step 8
Measure 5” across, and 5” down, from the top of your 2x10 sides. Make a mark.

Get your drill out, and drill a hole for your rope.

Thread your rope through the hole, and tie the ends in a Figure-8.

Step 9
Cut a 4” length of nylon strap. Thread 2x D-rings onto it, and fold it over.

Screw this to one side of your 2x10, somewhere above the hole you drilled for your rope.

Step 10
Get the rest of your nylon strap. Go to the other side of your pannier, and screw this strap to the 2x10

Now you have a simple and robust way to keep the lid closed when needed

Step 11.
Done. Finish the panniers with paint or spar varnish.

Total weight = 16.73lbs. (Lighter than some of the plastic ones out there)

***

EDIT: Ran out of room. See Part 2 below.

 

[yycyak]

(Part 2 cont'd)

Q&A

Are these waterproof? No

Are these bear proof? No

How durable are these? Depends on how bad the rodeo is. But should hold up to most abuse. The “two-by” fronts and bottom really add strength. I've seen guys take old used up latigos and screw them to the front corners and edges, almost like angle iron, to add some extra protection.

How heavy are these? Roughly 17lbs per box.

This is dumb, and my daddy and his daddy always did 'X'. Well, okay. I'm learning when it comes to anything to do with horses, there's lots of different ways to accomplish the same thing. This is my way.

We use manties, this is dumb. There's a lot of different ways to do things. Packing I find is a hugely cultural thing, and different regions do things very differently. I'm up in Alberta, and like hard panniers.

Your design is dumb and nobody ever built panniers this way. Could be, but I mostly just followed the below pictures as a guide. I figured if Col. Whelen ran them, they probably are legit. (I just made mine a bit bigger, referencing Joe Back's picture)

I'm a woodworker, and you could do X instead. Appreciate the feedback - Post it in the thread here. I don't do much carpentry anymore, so if there's a better way to improve on the build quality, I'm all ears. Version 2.0 is never a bad thing.

$28? C'mon man. See spreadsheet calcs. Maybe I missed something. These are in CAD$, so you Americans can probably do it for even cheaper.

***

Well that's all. Good luck to everyone out there this season.

 

[mcr-85]

We have some old wood panniers in the barn. I'll get some pics and post them here.

Sent from my SM-S908U using Tapatalk

 

[Grassymike]

Those are going to work . I used to have two horses and still have all the pack stuff . I am also a carpenter and have a full time cabinet shop. I would suggest 1'' plywood instead of the 2x8 or 2x4. Also cut a slight curve on the back side of the pannier like in the picture from Joe Back's book. That and a good diamond hitch will help hold your pack when the Rodeo starts. Good luck. I have a bunch of sources and information on horse packing gear ,Pm me if you would like .

 

[yfarm]

Instead of plywood use fiberglass bathroom panels with a 1x2frame, tape the seams with fiberglass cloth and resin, suspect you can cut your weight in half, straps out of seatbelts from a junkyard. Panels are easy to work with and internal panel could be bent to follow the flanks.

 

[yycyak]

Why use 1" plywood instead of 2x4 / 2x10? I have my guesses, but I'm curious to hear the "why" from a pro.

Those are going to work . I used to have two horses and still have all the pack stuff . I am also a carpenter and have a full time cabinet shop. I would suggest 1'' plywood instead of the 2x8 or 2x4. Also cut a slight curve on the back side of the pannier like in the picture from Joe Back's book. That and a good diamond hitch will help hold your pack when the Rodeo starts. Good luck. I have a bunch of sources and information on horse packing gear ,Pm me if you would like .

 

[Grassymike]

It is way stronger. The 2x material will likely dry and crack especially the 2x8. The other option would be to reinforce the front edge (when on your horse) of the boxes with fiberglass wraped around. Horses tend to smack boxes into trees etc. the plywood is more stable dimensionally as well, it won't twist or cup.

 

[Pony Soldier]

I did the same thing in 1980 only I modified on of the boxes into a chuckwagon with a fold down instant kitchen. The matching box contains the stove and cook gear. The other two panniers carry kitchen suppies, food, paper goods, etc.

I rounded the inside to fit the horse's sides and give me a flat top for the top loads. The boxes go on with a basket hitch that allows movement in tree conflicts. The top load goes on with a double diamond hitch that keeps everything stable.

Other than personal gear in backpacks the arrangement will provide all the supplies you need for a two week camp for four. I have run a camp for a month with periodic resupply trips.

I have used the same panniers for car camping on my job for over 30 years as well as helicopter camps. The supply panniers double as seats in the kitchen as well as providing rodent proof storage.

 

[doverpack12]

Thanks. I’ve been looking for boxes but like you the price tag keeps steering me away.
I’ll put these on my list to build this winter

 

[rayporter]

i built a plywood set in 84 and used them for years. they even went on a float trip in Alaska.

 

[Jason Snyder]

Also cut a slight curve on the back side of the pannier like in the picture from Joe Back's book. That and a good diamond hitch will help hold your pack when the Rodeo starts.

This is the way for hard panniers.

 

[doverpack12]

This is the way for hard panniers.

1” at center of curve? More?

 

[Jason Snyder]

1” at center of curve? More?

More. I’d probably go about 3-4”.

 

[Grassymike]

I just went and measured one of my plastic pannier boxes in the garage and mine are exactly 1'' in the center of the curve.

 

[Grassymike]

The box dimesions are like 20' tall, 8.5'' wide at the bottom and 10'' wide at the top. (end of pannier) 22'' width. This is a plastic pannier box made by Custom pack rigging from B.C. More curve could very well be better this is just what my production box is. ONe size fits all . Might not fit a fat horse as well.

 

[Pony Soldier]

Try this folks. Worked for me for 45 years.

 

[Jason Snyder]

My preferred method was manties. Cheap. Easy. Versatile. Hard to break.

 

[Pony Soldier]

You folks are making me work at this. The correct way is -- everything. I use my wooden panniers for my camp. I use canvas panniers with leather ends for irregular items. Recently it was chainsaws, hind quarters of elk, chains rope and at one time even gold bearing placer gravel.

I use manties for elk quarters, sleeping bags, hay, and various irregular objects that don't fit anywhere.

On top of that I have just tied things on like pumps, sluice boxes, tools and things you just can't imagine.

Diamond hitches, double diamonds and an endless amount of hitches you have to know without thinking.

Be flexible!! Match the need to the use.

 

[yycyak]

Oh man, I wish I was that skilled. But cutting matching curves and bending plywood is a bit beyond my talents. Colonel Whelen's drawing caught my eye mostly because it avoids the "Be a talented carpenter" issue.

This is the way for hard panniers.

 

[Giles19]

Canadian here as well. A set of Pokiak Plastic kitchen boxes will run a guy $380. Will weigh probably 12lbs less per box, far more durable, and water tight except for the lids. 99% of the time (except for trail cutting) I'm using hard boxes.