Sometimes our customers want all the solar charging functionality of our bags but in a different form. Benjamin Morrison, an avid cyclist, wanted to solar-ize his panniers and produced one of the nicer mods we have seen. These are his instructions from the project.
Step 1: Parts and Tools:
Three 1.3 Watt Solar Panels – $90
JetPack Battery Pack – $75
Circuit Box Set – $3
1 used Backpack shell – Free, just ask us
Cloth-Riveting Tool (available at hardware and craft stores)
Cloth-Rivets, Match Size to Tool
Corrugated Plastic Stock
1/4” Grommets and Applicator Tool
Parts solar panels and battery pack
Tools:
Steel Ruler
Scissors
Hobby Knife, Scalpel Blade
Anti-Frey Compound, “Frey-Check”
White Cloth-Marking Pencil
Super-Glue, Any Brand
Black Electrical Tape, Indoor-Outdoor Quality
Step 2: Remove panel frames from old bag
Use the scalpel blade to sever the threads holding the three solar panel frames to the front of the bag. Simply stretch the fabric at the seams till the threads are exposed and cut with downward pressure. Then slide the knife along the seam. Use this time to apply Frey-Check to the seams of the pockets, use liberally.Do the same for the pouch at the top of the bag as it will make a nice holder for the battery.
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Cutting the solar cell pockets apart is tricky, take your time and use the ruler to guide your hobby knife. Then use scissors (or the knife if you prefer) to clean up and round the edges.
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Step 3: Remove bag handle from Pannier
If the handle on the bag is in the way, use the scalpel blade to remove it by slicing between the bad and the handle, severing the stitches. If you feel your bag must have a handle, it can be moved in between two solar cells, to the left or right (or wherever you want), but sewing will be required to re-attach it.
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Step 4: Create template for attaching frames
Measure the size of the individual frames, create a template. This will be used to mark where rivets will secure these to the bicycle bag. Using three in a triangular form makes for a strong hold that is still flexible.
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Step 5: Mark Placement of Frames on Pannier
Cut out the template and use your cloth-marking pencil to mark where the rivets will be placed, both on the pockets and the bicycle bag.11
Step 6: Punch holes in pannier and frames and rivet together
Use the Riveting tool to punch the appropriate holes where you have marked them previously, both on the bag and pockets. Follow the instructions included with your riveting tool to rivet the pockets to the bicycle bag. Make sure the openings in the pockets all face one direction or wiring will be much more difficult. Note: In the image above such a mistake was made and some creative use of electrical tape and the knife was needed.Do the same for the battery pouch on the interior of one of the bags pockets. Either side is fine, but have it closer to the front of the bike.
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Step 7: Create channel for wire from panels to battery
Cut a hole from the underside of the bag into the side that contains the battery pouch. Do this toward the front of the bicycle-rack. A slit will do, use super-glue around the slit to prevent tearing.
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Step 8: Install the solar panels
Slide your solar panels into the frame and connect them to the circuit box, tucking the box under the bag for protection. Guide the cable through the slit.
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Step 9: Seal the panel frames
Black duct tape may be used to close the edges of the solar cell frames and give a more finished look. Do not use electrical tape as it tends to react poorly to the heat from the panels.
Step 10: Make the electrical connections
Plug the Cable from the circuit box into the battery pack, attach whatever adaptors you wish and place the battery in the pouch. Pictured is the car-charger socket.
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Optional: The LED indicator light was not used in this project, if you wish to mount the LED, use a ¼ inch grommet and application tool.* This can be found at a local craft shop. The LED will fit snugly into the grommet.
The finished project. The side panels will lay at 90 degrees to the sun when the pockets are full, or you may use corrugated plastic stock to support the sides of the bag.
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Editors note: Solar panels produce the most power when the cells are perpendicular (90 degrees) to the sun’s rays. To charge the Voltaic battery efficiently, you want to make sure all three panels are able to point directly at the sun.

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