To make your DIY bike bag, you only need to find plastic cans, cut them out, and mount the parts. Here is what you find in this tutorial:

Detailed step descriptions

1. Cutting plastic cans

2. Mounting the upper strap

3. Mounting the side straps

4. Mounting the hooks

5. Mounting the third point of suspension

x. Tightening the screws (torque)

Materials

The Cannier set

Finding plastic cans

Or:

Producing your own parts kit

Tutorial overview

For the actual making of a plastic can bike pannier we recommend reading the detailed steps. 

Materials needed

(for a single pannier for one side)

2x Plastic cans

1x Parts kit containing a strap assembly and suspension system. 

There is a complete chapter in our tutorials, dedicated to producing your own parts kit. If you want to skip that, you can order a Cannier set from us.

For one Cannier you will need two identical plastic cans. They have to be identical, otherwise they will not fit each other. Choose cans made of High Density PolyEthylene (HDPE or PEHD). This material is the most common. Find cans that have the same shape on the top and on the bottom.

Tools needed

The best tool for cutting is a jigsaw with a blade for wood cutting. The best tool for making the holes is a drill with wood bits. Using powertools can be dangerous – ask for help if you are unsure. For turning in the screws you will need 3-4-5 mm hex wrenches, and 8-10 mm tubular or open end wrenches.

Cutting the cans

1. To start making your DIY pannier, cut two plastic canisters: one for the bottom part and one for the lid. Mark the cans before cutting. Cut the bottom part first, leave the top (lid) part second.

2. Bottom part. Cut an opening on the bottom part. Leave a little bit of the inward curve on at the edge of the opening to improve rigidity. You will need to curve the cut below the mouth of the can. Cut as close to it as possible.

3. Lid: The lid will have to be able to slide on the bottom part. When marking the lid, place front to the front, rear to the rear. The front part will have to be cut lower to cover the space left behind the mouth of the other can.

The straps

4. Drill two holes on the lid for the handle. Mount the upper strap with the screws. Please make sure that the embroidered label on the upper strap is on the rear side of the Cannier.

5. Push the lid down on the bottom part, and pull down on the strap adjusters. Mark the holes for the side straps 2cm below the lid and the strap adjuster, but try to stay close to the lid.

Suspension

6. Find the right position of the pannier on your bicycle. Bring the Cannier as close to the center of the bicycle as you can. Sit on your bicycle and pedal backwards to make sure it doesn't touch your heels. If you tilt the pannier forward, you can bring it closer.

7. Hang the two hooks on the rack as further apart as you can, but with free space on both sides of each hook. Hold the pannier in the position that you have found for it in the previous step, and mark the holes on the side of the bottom part.

8. Screw the clamp and the one-eyed rabbit steel plate together on the rack. Place it as low as you can, below the middle of the pannier.

9. Hang the pannier again, and mark a dot on it through the bottom of the opening in between the rabbit's ears. Drill a hole and mount the quick release. Turn the nuts on the quick release until it locks the rabbit with comfortable finger pressure.