Vario pannier broken plastic lug fix ?

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  1. #1
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    2005 Dakar
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    Default Vario pannier broken plastic lug fix ?

    After a low speed off I have broken one of the plastic mounting lugs on the rhs pannier.
    Has anyone got a good 'fix' for this before I set too and use araldite and keep my fingers crossed it holds out...
    The pannier still sits ok with just the one lug and the top fastener but does move around a bit and catches on the exhaust shield.
    I see these vario panniers for sale quite a bit with said broken lugs (not surprised, they can be a bigger to mount and remove without resorting to brute strength !) ,so I'm hoping someone has a miraculous fix...

  2. #2
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    '02 GS Dakar
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    Yes. A similar thing happened to me a few years back and I bought a right angle bracket from B&Q which was a perfect fix and is still going strong. My pannier lug was swinging around and the B&Q bracket was a perfect fit over the top of the original lug. So, the lug is retained and the bracket supports it, this way it still fits the rack perfectly.

    The fix worked so well I reinforced the other lugs in the same way. The bracket is in the ironmongery section and is a dark brown colour, so you don't even notice it's there. PM me your number and I'll text you a picture of it.
    BMW '02 GS Dakar
    Honda 954 FireBlade - sold
    KTM 525 EXC Racing

  3. #3
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    Brilliant Cyclos, sounds just the job.
    Will send a PM.

  4. #4
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    Hello,
    Could you post a picture of your fix on the forum, I'd be interested in seeing what you did.

    Thanks

  5. #5
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    Quote Originally Posted by Toad View Post
    Hello,
    Could you post a picture of your fix on the forum, I'd be interested in seeing what you did.

    Thanks
    Hi Toad,
    Not sure if your request was aimed at Cyclos or myself.
    I will post a pic when I get round to fixing it. I live 90 miles from my nearest B&Q so it may be a while unless I can source something similar locally.

  6. #6
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    Quite right I meant to ask Cyclos if he could show us his fix.

  7. #7
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    '02 GS Dakar
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    Here is is, you can see one of the lugs is missing, the other is still there. Apologies for the state of the pannier, but I commute on it!


    BMW '02 GS Dakar
    Honda 954 FireBlade - sold
    KTM 525 EXC Racing

  8. #8
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    Default Photos

    Why is posting pictures on forums always such a pain!?
    IMG_0864.JPG
    IMG_0865.jpg
    IMG_0866.jpg
    BMW '02 GS Dakar
    Honda 954 FireBlade - sold
    KTM 525 EXC Racing

  9. #9
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    Just found this I have done the same so will give it a go
    Quote Originally Posted by cyclos View Post
    Yes. A similar thing happened to me a few years back and I bought a right angle bracket from B&Q which was a perfect fix and is still going strong. My pannier lug was swinging around and the B&Q bracket was a perfect fit over the top of the original lug. So, the lug is retained and the bracket supports it, this way it still fits the rack perfectly.

    The fix worked so well I reinforced the other lugs in the same way. The bracket is in the ironmongery section and is a dark brown colour, so you don't even notice it's there. PM me your number and I'll text you a picture of it.

  10. #10
    Bike
    '02 GS Dakar
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    Sep 2009
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    Cornwall
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    It’s a good, cheap fix that works really well. Sold my Dakar last week and the panniers were still going strong, over 10 years later!!
    BMW '02 GS Dakar
    Honda 954 FireBlade - sold
    KTM 525 EXC Racing


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