When I purchased my F650 GS the previous owner built his own pannier system from US army aluminium food boxes. I had a few problems with this - first off, I didn't like the round looks of the aluminium boxes and 2nd I have countless ammo boxes that I have already built pannier holders in my LT, TriStar and Westfalia, so it would only make sense to use these boxes on my bike.
Seeing how I don't have a pipe bender, I set out to build the ultimate pannier racks using 18mm (3/4") square tubing - rack is 320 x 220mm on the outside diameter and is mounted to be parallel to the rear rack. Building it from square tubing also will lead to a more positive locking system for the panniers.
TIG welding of pannier racks
Test fitting of pannier racks
Rear support of pannier racks
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