Originally Posted by
chaadster
Interesting concept.
I did think about some alternative materials for the box, namely coroplast. However, what I keep coming back to is the durability/ruggedness of the material - think wrecks and other mishaps here. Aluminum is likely to deflect a lot more than would coroplast or fabric.
My panniers are Ortliebs. I do have to say they have surprised me on durability. I did wreck on my trip. I was riding across a wood bridge that was wet with leaves. I went down very quick once I was on the wood I was down and sliding across it sideways. I was not moving very fast trying to be careful, but on to the wood and down I went. I didn't damage any panniers on the side I fell against, but I did put holes in my other dry sacks.