Hi guys,

Didn't know in what category my request falls, so I do it here as it seems the most proper. Recently, I had access to an Ortlieb-like fabric. To be more correct, it is an inflatable boat fabric of the type vinyl coated polyester and I tried to make a handlebar bag.
The first attempt wasn't successful, the second is better. I used a heat gun to weld the parts. However, the following issues popped up:
1. At  what stage of the making do you attach/ sew thee zipper? Is it the start when you have cut the different parts of the bag and still have not started welding them together? If so, how do you protect the zipper from melting?
2. How do you arrange the waterproofness of the zipper and the sewed fabric around the zipper?

As you can see from the attached photos (the first two photos show the first bag, the remaining three photos are the second bag), I have sewed the handlebar attachment anchors to the PVC fabric. However, I sewed them after I measured and cut the fabric and it was easy for me to weld pieces of PVC fabric on the inner side of the bag in order to make it waterproof.

As for the zipper, my first attempt was to sew initially it prior to starting the welding process. However, most of it melted. In my second attempt (the bag with the cylindrical form), I sewed the zipper last. I thought that the waterproofness would be established by making a zip-cover. But the issue was how to make that zip-cover.

I cut a longer piece of fabric to weld to the circular side walls so that extra fabric would remain. The extra fabric would be doubled so that the one side match the other where the zipper would be sewed. Doing so, I had an issue how to weld the doubled piece with also leaving at the same time a sufficient breadth for sewing the zipper. I am opening a bracket here by saying that the heat gun is with an ordinary nozzle with an air flow of 2 cm which is not narrow enough and I was not able to make the cover. I came to the conclusion that without using glue, it would not be possible to complete the project. What I did was to stitch together the doubled fabric and cover the stitches with glue.

Of course, the easiest option is to weld a separate piece of fabric above the zipper. But the reason why I wanted to make a double cover (at least during my first attempt) was to use the space for storing things like documents or other smaller items. On one of the photos there is a vertical slit on the inner part of the cover.


So I would like to know, in addition to my questions above:

3. What glue you use for Ortlieb-like fabrics? There are loads of types of vinyl plastic adhesives but the prices vary extensively. So what is the best price/quality option.
4. At what distance from the zip you sew the handlebar attachment anchors? Mines are roughly 4 cm below the zipper but the bag sags. what if you make a bag with square sides
5. The bag sags the furthest from the attachment points and it is difficult to unzip it with one hand only. So if I put something heavy inside and need it while riding, I cannot unzip it. Some people would advise me to put a plastic piece inside the bag but I would like to know how to make it firmly attached inside.
6. If you cover the zipper, how do you secure/ unsecure the cover while riding?

Thanks.

Although a quite old topic, I didn't want to start a new one.

Actually the review from bikepacking.com gives quite a good idea for a diy easy project. However, what I'm concerned about is the strength of the material. Shared experience would be great:

https://bikepacking.com/gear/wayward-riders-louise-dropper-post-harness-review/

I actually achieved quite success just by using bungee cord around my seatpack. The bungee cord passes though the rails, around the bag and its ends are connected by a carabiner. Although the instability of the bag isn't 100% removed, it is quite effective.

One has to grab a piece of bungee cord, make a ring and voila.

Regards

Well, the lash straps were used for for securing the sleeping mat, etc. items under the handlebar -->  http://www.bikepacking.net/forum/diy-make-your-own-gear-(myog)/super-simple-handebag-bag/

As for the Voile straps vs bungee cord, I'd say that the latter is much better. Reasons - its length is greater, it's a DIY, it's been used on previous occasions with greater stresses and nothing was lost, the risks of detaching are limited because, instead of using a hook to connect the ends of the bungee cord, I use a maillon or carabiner (refer to the first photo)

Regarding the concerns of closeness of the bags to the wheel - as you might notice, the bags are actually secured to the fork (the last two photos of my first post). The half pipes are used to restrict the sideways motion of the bags.

As for the cracking, it is marked with red. I assume the reason for the crack is because the bags were attached at one point only and when passing through bumps, the dangling of the bags affected the strength of the pipes.

Hello bikepackers,

Several days ago I returned home from a bike road trip (well, 99% of it was road). In prepaation for it, I decided to neglect the fact that I have a rear rack and use a DIY attachment on my fork instead.

For the purpose I used a 5" pipe, 10" long cut into two halves, each half attached independently with hose clamps on on the two sides of the fork. It did a perfect job and the bike was stable.

However, I did notice two issues during and after the ride. First, I hadn't drilled holes for adjusting the brake pads in case it was needed.
Secondly, when I was home, I noticed that one of the half-pipes had started cracking.

Regarding the modes of attachment of the bags (one was of hardcore material 20 l dry bag; the other - 20 l OR very light dry bag) - I used two bungee cords.

My observations - although the bags were really very well attached to the fork, wowuld it not be better to use two bungee cords in order to secure the upper and the lower part of the bags instead of using only one for securing the bag in the middle? This way, I think, I will be able to avoid the bulging of the top and the bottom parts of the bags as well as avoid putting too much stress on the points of attachment of the half-pipes to the fork. In addition, any advice regarding limiting the friction beween the bag and the bungee cord will be highly appreciated.
If anybody has used similar attachments, please comment and share experience.

In addition, I tried the method of attaching lighter items as a sleeping mat, a helmet and other smaller items under my handlebar. I used the instructions http://www.bikepacking.net/forum/diy-make-your-own-gear-(myog)/super-simple-handebag-bag/ and a longer bungee cord. It also performed perfectly and didn't mess around my hands as was before.
There are some photos here:

I will definitely give the Ortliebs a try. But I am more apt to think that they are not going to stand the tests of brutality.
Time will show. Thanks though for your opinions

Thanks for the answer

It seems that the only option is back-bikepacking. Or it might also be with self-made bags with diy attachment hooks.

What about the attachment mechanisms of the Ortlieb bags - how much can one count on them?

Hi there!
I am quite new o this forum and this section is not the proper one to introduce myself. That's why I go directly to the questions.
Since I am a fan of bikepacking and, at the same time, as less luggage as possible on my back, I" would like to have the opinions of packers who cycle dirt roads with panniers. I would like to know the most durable and worth investing panniers for such occasions.

Now regarding my experience:
I got access to a pair of Kangaroo baggs that I used really hardcore during two of my trips each taking about 20 days.
My first trip was mostly asphalt with elements of dirt. What I noticed at the end of the trip was that the solid part of each pannier (the one that rests on the bike rack) started cracking.
In order to reinforce the panniers, I decided to remove the hooks by unbolting them and add washers. This being done I started my second trip which was 99% paths covered with stones.

The first day involved about 20 km dirt road with loads of stones. What happened then was that initially my first pannier detached from the rack - the jolts had unscrewed the panniers - and a little bit later the second pannier fell apart.

On a close look I noticed that the bolts had not been firmly screwed. I did some on-scene repair and kept on moving.

At the end of the trip I accounted for the damages. First of all the solid part of the panniers which is aluminium was torn. I started wondering whether it is worth investing in another set of panniers. Knowing that Ortlieb are, according to a guy I met on the road, the best of the best, I got access to those panniers. However, what I noticed is sort of dissatisfying to me. The solid part is a flexible plastic, much less stronger than the aluminium of the Cangaroo baggs. Secondly, the attachment points are made of plastic. Are Ortliebs reliable enough for such exploitation? If not, what are the most suitable panniers?

Thanks in advance,
Ognyan

PS: having in mind that almost nobody uses panniers during their trips, I assume that pannier investment is a waste of money.

THe attached photo is one of the damaged panniers