The OEM panniers are not cheap, on top of the fact that RE only sells in pairs (so if you fall to one side and need to replace one - tough luck!) they do NOT offer ANY replacement parts whatsoever. If you lose the keys you can not just replace the lock because it is fixed with rivets. If you decide to bore them out you still wont get a replacement lock (although I may have found a source - contact me if you need one).
I purchased one box from a dealership who omitted to tell me that one of the inner locking mechanisms was fully missing. If you look at this mechanism you realize that the OUTSIDE plastic round part is not easily replaced by something else (and still keep the simple mechanism this provides) - so it had to be 3d printed.
Likewise the big wheel inside with which one locks the upper locking mechanism is a plastic wheel (this could be replaced by a nut with some "wings" welded to it but it would be ugly and could rip into stuff you store in the box) - so another candidate for 3d printing. The L shaped bolt with the handle that rotates on the outside to lock the pannier to the carrier is easily replaced by a bolt of similar size and length welded to a rectangular piece of metal of the same length and width but not necessarily the same thickness (it can be thinner and will work just as good).
So with the help of @barima of kick-start fame I had the inner and out parts designed in a 3d program and printed locally for about 5 bucks each. That is not cheap but it is way better than not having the locking mechanism at all. With work and design and welding and parts it came to 30 Euro for the whole shebang.
here you can see the knob (inside the box) and the outside round part that locks to the carrier.
I purchased one box from a dealership who omitted to tell me that one of the inner locking mechanisms was fully missing. If you look at this mechanism you realize that the OUTSIDE plastic round part is not easily replaced by something else (and still keep the simple mechanism this provides) - so it had to be 3d printed.
Likewise the big wheel inside with which one locks the upper locking mechanism is a plastic wheel (this could be replaced by a nut with some "wings" welded to it but it would be ugly and could rip into stuff you store in the box) - so another candidate for 3d printing. The L shaped bolt with the handle that rotates on the outside to lock the pannier to the carrier is easily replaced by a bolt of similar size and length welded to a rectangular piece of metal of the same length and width but not necessarily the same thickness (it can be thinner and will work just as good).
So with the help of @barima of kick-start fame I had the inner and out parts designed in a 3d program and printed locally for about 5 bucks each. That is not cheap but it is way better than not having the locking mechanism at all. With work and design and welding and parts it came to 30 Euro for the whole shebang.
here you can see the knob (inside the box) and the outside round part that locks to the carrier.
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