When I went down (three times) trying climb up to Hayden’s Pass in Colorado my panniers took a beating. Mostly because I made sure I dropped the bike on both sides, you know, to be thorough. My boxes did okay. A few more dents and scrapes and I managed to crack two of the other welded edge seams. I’m waiting for our new press brake to arrive to make the angle to strengthen them.
The damage to boxes turned out to be the least of my problems. I managed to break one of the box mounts on the right hand side completely off. It was going to need welding. Good thing I’m a TIG welder by trade.
Here’s how it looks without all the wire. It’s a complete separation right on the edge of the weld area. Whoever did the original work put a little too much heat into the tube because the failure was right on the edge of the weld.
A closer look at the break.
All in all it was an easy repair and only took about an hour.