How to Make Kitty Litter Bucket Panniers - One Heart Fire

oneheartfire.org
A step-by-step instructional video of how to create your own bicycle panniers, or saddlebags, out of the square buckets that kitty litter is sold in. I am currently using these panniers to carry my gear on the One Heart Fire permaculture bike tour, visit oneheartfire.org for more info about the tour, our personal blog, as well as other DIY and permaculture related articles and videos.
Here is the materials you will need to make a single pannier:
1 35 pound kitty litter bucket
4 wood spacers 1/2" x 1 1/4" x 2 3/4"
2 wood spacers 1/2" x 1" x 2 3/4"
2 6' x 3/4" metal brackets
6 1/4" x 1" hex bolts
4 1/4" x 1/2" hex bolts
10 1/4" nylock nuts
4 1/4" x 3/4" fender washers
4 1/4" x 1" fender washers
6 1/4" x 1 1/4" fender washers
2 3" extension springs
2 1/2" x 1" L brackets
1 1" welded ring
6"-10" of nylon strap
All of these materials should be easy to find at your local hardware store, I purchased mine at a true value store, except of course the kitty litter buckets. Bring this list in and the employees should be able to help you find it all.

[@XandyXChristX]

The RK2575 Jandd Pannier J Hook with Rubber Protector is available now from many online bike shops, save yourself the trouble of bending those brackets into hooks with the torch and all. Also the M-Wave touring rack with drop rails comes with a loop on the bottom so you could just use a doubled up bungee instead of the springs and metal ring, probably a little cheaper and easier.

[@exodous02]

acitone wipes the graphics right off without damaging the bucket

[@mo-reesespieces9066]

What a great idea. One thing I would do to protect the basket. Wrap the basket with any colored Duct Tape you like. Plastic buckets over time and with sun damage will get brittle and crack. The tape should protect it from the sun, and in the event you do have damage and it cracks, the tape will hold it together, add strength, and prevent any plastic from breaking off. I basically did the same thing making a pack basket for trapping. I used an old aluminum pack frame. I did not want all my hard work to just get brittle and break over time so before I attached the basket to the frame I wrapped it in Duct Tape hopefully adding years of usage to the basket without it becoming brittle and breaking apart over time. Peace

[@beaubryant8381]

Hey, thanks for showing how to mount the springs and ring for that extra little bit of added tension. Right now I'm using two pieces of kid's roller luggage with pegboard attached to the back to make some panniers for my bike. Now that I know how to mount the spring, I'll definitely be using this little hack! Also, great job on the filming! It's SO much easier to watch these DIY videos when makers like you keep the instructions concise, and plan out their steps, materials, and video angles ahead of time!

[@eliothoward2128]

Clearly a brilliant idea! Thanks for sharing. There are probably a million small personal tweaks one can make, but here is one improvement idea that stood out to me: how about using countersunk barrel nuts for the main load-bearing attachments, and perhaps rivets for the lower (spring & strap) attachments? These might make that interior surface of the buckets smoother/less snag-prone. Again thanks for sharing this project!

[@eliothoward2128]

www.google.com/search?safe=active&rlz=1C1SQJL_enUS763US763&ei=M7iLXL6BPcWIsQXq_qKIDg&q=countersunk+barrel+nuts&oq=countersunk+bar&gs_l=psy-ab.1.0.0i20i263j0i22i30j0j0i22i30l6.30209.41020..43675...0.0..0.70.1008.17......0....1..gws-wiz.......0i71j35i39j0i131j0i67j0i10.Ez_1OWT5-EQ

[@jennydances]

Just wanted to say thank you for creating such a good quality video with easy to understand instructions and tips..."if you find....then just..." My boyfriend and I are preparing for one of any possible futures, and watertight panniers might be part of the picture, so we'd likely use your video as a jumping off point. I know how much time must have gone into creating the vid, so again, thank you.

[@buttermybutt2659]

Okay, I was going to make panniers out of kitty litter buckets using one of the techniques similar to this video or other videos using hooks, bolts, etc. Then I went down to the local hardware store and the clerk said he would strap them on using bungie cords. So I had some of them at home and they worked great. No drilling, measuring, nuts or bolts and hooks to install. Butt I did use the type of bungie straps that semi truck drives use for the top strap. The rubber ones with the metal hooks. They are very strong and can support a lot of weight without stretching much. They are sold at hardware stores, just get the correct size. There is a space right at the top of the bucket that the strap goes around and then you just hook it to the rack. For the bottom strap I used the type of bungie strap that are made of stretch nylon with rubber to hold the bucket tight against the rack. Works great!! When installing the rubber strap be very very careful. They can cause injury if they slip and the metal hook catches your hand.

[@buttermybutt2659]

Here is an update on my way of making the panniers out of kitty litter buckets described above. I found out it works great for light loads, 1 to around 15 pounds. If you put more than that amount in one of the buckets you might get some sag. When I had a gallon of milk, 5 pounds of aquarium gravel, a couple of 16oz cans of food, and my lock plus cable in the bucket the other day, by the time I got home the bucket had sagged down some which could be a problem. Butt like I said it works fine for light loads.

[@Arthur-Silva]

Well done!

[@PersonalVideos2008]

Very well done video! Have you considered using one 4" piece of wood spacer instead of the two smaller pieces? That would give it more stability, require 1/2 as many cuts, and let the wheight rest on the outside "lip" of the bucket (reducing load on the bolds)

[@Hootyhoo-jq9vq]

Cool video.

[@fuelman123]

nice job!

[@jgrimesphoto]

You could do the same design for front panniers, but smaller buckets would be better. There is a bit of wind resistance with these for sure, but you can sure carry a lot.

[@merakwg1]

great thanks!

[@Vezperal]

To tell you the truth, my panniers just broke down and I felt like screaming. I don't have money to buy another set. Your video just made my day (hell, month!). Thank you a billion! Would you have a suggestion for front panniers? Probably smaller boxes? And how are they for wind resistance?

[@stevemccray650]

I noticed he was what appears to be an aluminum top bracket,is that what broke?I used A/C duct zip ties.They are really long and heavy duty.I've had it weighed down with at least 50 pounds and never having an issue except rattling when empty.

[@justinbarney8198]

Given your tone and how well you speak, you should def considering being an Instructional Guide for a living :)

[@jessegrimes1896]

I do teach workshops on occasion. Mostly I am a permaculture design and natural building contractor.

[@vonketelsen430]

Hey Jessie! Thanks for the video! I have four 35 lb kitty litter buckets, from my neighbor. Can I have 35 lb buckets on the front and back, or should I get smaller buckets, for the front? I see JANDD offers a kit for making panniers out of buckets. Any thoughts on that?

[@TheMichiganterry]

Just the first little bit when you went over what I needed I decided I'd rather buy a pre-made bike bag.

[@patches_kitty]

TheMichiganterry If you ever want a good simple box pannier, good luck! I saw this video a few months ago and now that I'm looking for box panniers I've come back because there are no other options. And I have the kitty boxes, so why not.

[@stevemccray650]

It's called improvision,try it out some time..

[@Moradiss]

Great idea though you may want to cut your wooden spacers with the grain running along the long plane for more strength

[@Moradiss]

Forgot to add, to make his in the nylon strapping heat the top of an old Phillips screwdriver that is slightly smaller than the hole you need. This has the added benefit of preventing the hole from fraying

[@Handygrrl]

I would have used stainless steel hardware to prevent early rusting. Even tho it costs more, i don't like to make things twice. I might have also used treated wood. Thanks for the video.

[@allanb52]

You can't soften steel until it is red and you cannot temper mild steel.

[@christjulipds13]

You can learn more about it on woodprix website I think.

[@cwitham69]

Acitone doesn't work that well. I use the aerosol 'CitriStrip' paint&varnish stripper gel from HD. Let a thick coat sit for 8-10 hours on one side panel at a time. Use a plastic scraper to remove liquefied label to an old plastic food tray. Wipe down with mineral spirits & paper towels. Remember to wear nitrile gloves & safety glasses in a ventilated area!

[@buckettraveler8398]

I made my own, rode to Panama, and then flew back WITHOUT my bike. Ran out of money and didn't even have money to fly with my bike. Now I'm building a new set for my old bike and I think I'll go with some clips made by Arkel. They make an aluminium set, search Cam-Lock® Hook Kit or look under accessories on their site, that look really tough that can be attached to anything. A set costs $50 but eh, it looks like they will work well. If you get the buckets for free maybe they will end up costing $20 more. I have seen a few 'bucket kits' online that cost $35 to do a set of panniers, without buckets, and while they look alright they don't look anywhere as good as the Arkel Cam-Lock® Hook Kit.

[@whateverrobert]

A lot of holes. I would have use a bungee cord and use the bolt holes. Less holes less leaks or cracks.

[@romeliadarosa4180]

I am sure you can still buy handbook with all info you need on woodprix. Just google it.