Category Archives: Modifications


Protecting your Bike Racks

Ortlieb panniers come with small plastic inserts to allow a snug fit to a variety of bike racks. There have been numerous reports from other cycle tourists that these inserts can come loose and get lost resulting in a rattling rack set up.

On a long tour the pannier mounting hooks can also get a lot of wear and tear as can the pannier racks themselves. Repeated rubbing against the rack rails can damage the powder coating and steel racks can begin to rust. Having seen other bike tourers’ attempts to reduce this with gaffer tape or other material with some success I decided to try a more robust solution to address both problems.

After scouring the internet I found some reinforced clear plastic tubing with an internal diameter of 10mm (the diameter of the tubing used on Thorn steel racks) and an outside diameter of 15mm (slightly smaller than the 16mm Ortlieb pannier mounts without an insert).

Reinforced tubing used to protect rack

The tubing and tools required … oh, and add some zip-ties

Thorn Low Loader Mk V with protective tube

The finished front Thorn MkV Low-Loader

Rear rack covered in tube protection

The finished rear Thorn Expedition rack

After the North Sea Cycle route tour of about three months in 2013 there was little noticeable wear on the protective tubing. After the second trans-Europe tour in the Summer of 2016 there was still little wear on the rack tubing.

It works well and is not an expensive solution!