What do I replace coroplast with in Sackville

[Joe Bernard]

Mine is all bendy and collapsey in my medium SaddleSack. What are you folks putting in there to replace it? 

Joe Bernard 

[Pam Bikes]

The signs posted for political campaigns that are sometimes never taken up are coroplast.  Remove the sign since it's litter and use that.  I can send some if you have the measurements.

[Jay Lonner]

I’ve been thinking about this as well. Replacement coroplast is the obvious answer, and I’ve saved a stash of campaign signs from last November’s election for just this purpose. But I’ve also been thinking about getting rid of the coroplast entirely, and zip-tying something like a kitchen wire cooling rack (like for baking cookies) to the top of my rear cargo rack to provide support to the saddlebag from underneath. This would probably be more durable, and would also eliminate the problem of small items diving underneath the coroplast inside the saddlebag. I’ll be curious to learn what clever solutions others have come up with.

Jay Lonner

Bellingham, WA

Sent from my Atari 400

On Apr 17, 2023, at 8:06 PM, Joe Bernard <joer...@gmail.com> wrote:

Mine is all bendy and collapsey in my medium SaddleSack. What are you folks putting in there to replace it? 

Joe Bernard 

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[Joe Bernard]

That's brilliant, Pam! I never in a million years would have thought of campaign signs. Dimensions are 15x9 inches. 

Thanks!

Joe 

[Jan O.]

I just replaced the original coroplast from my small Sackville bag with Plastic Corrugated Sheets I found at Office Depot. I used two sheets, cut to size, for stronger support and masking tape around the edges to bound them together and cover the sharp edges.

Jan

San Francisco, CA

[George Schick]

I hadn't thought about using left over election coroplast signs for this application, but I will now.  Good idea.  What I have used, though is YUPO, an artificial paper.  It's available at art supply stores in big sheets and it can easily be cut to fit any bag dimensions.  It's waterproof. Plus, it's white so it brightens up the interior of dark bags so you can see what's in them better.

[Brian Turner]

Those hideous campaign yard signs were the first thing that popped into my mind as an abundant source of coroplast or corex. Might as well take something negative and turn it into a positive reuse!

On Apr 18, 2023, at 8:12 AM, George Schick <bhi...@gmail.com> wrote:

I hadn't thought about using left over election coroplast signs for this application, but I will now.  Good idea.  What I have used, though is YUPO, an artificial paper.  It's available at art supply stores in big sheets and it can easily be cut to fit any bag dimensions.  It's waterproof. Plus, it's white so it brightens up the interior of dark bags so you can see what's in them better.

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[Kainalu V. -Brooklyn NY]

As folks have said, more free coroplast will be the ideal solution. However, if you want to make your coroplast last forever, never to go “all bendy and collapsey”, send it around the front and back (or side to side) corners, bending it the hard way. To bend “the hard way”, you’ll want to score the coroplast before bending it. Use a straightedge and something dull to scribe your bend line perpendicular to the corrugations. You don’t want to cut the bends, just dent them enough to follow the lines you want. If you plan it well, you’ll be able to unfold your new insert inside the bag and it’ll lock into the interior dimensions, giving your bag structure forever and ever…

Happy bagging!

-Kai

On Monday, April 17, 2023 at 11:06:34 PM UTC-4 Joe Bernard wrote:

[Joe Bernard]

Oh I didn't bend it, it just collapsed under the weight of stuff in there. I carry a lot of stuff! 

[George Schick]

JB sez "... I carry a lot of stuff!.."  So do I and I'm beginning to wonder why.  I carry 3-4 different sizes of tubes in case I run into someone who flats without a spare along with an entire collection of small tubes, patches, etc.  Every time I lift it down from the ceiling hooks I consider ditching most of it.  I think I will...

[Jay Lonner]

I’ve looked more into the idea of an external saddlebag support, and wouldn’t you know it the good folks at Surly thought of it first: https://surlybikes.com/parts/tv_tray I just ordered one and will report back.

Jay Lonner

Bellingham, WA

Sent from my Atari 400

On Apr 17, 2023, at 8:46 PM, Jay Lonner <jay.l...@gmail.com> wrote:

I’ve been thinking about this as well. Replacement coroplast is the obvious answer, and I’ve saved a stash of campaign signs from last November’s election for just this purpose. But I’ve also been thinking about getting rid of the coroplast entirely, and zip-tying something like a kitchen wire cooling rack (like for baking cookies) to the top of my rear cargo rack to provide support to the saddlebag from underneath. This would probably be more durable, and would also eliminate the problem of small items diving underneath the coroplast inside the saddlebag. I’ll be curious to learn what clever solutions others have come up with.

[Tom Wyland]

I've been just sitting here waiting for someone to try a TV Tray in their saddlebag.  I have one of the old large Saddlesacks and the coroplast doesn't last long. 

Let me know how it works!

Tom

[Ian A]

In a set of Lone Peak panniers I used to have, the plastic stiffeners they came with  actually broke to pieces. I replaced them with thin sheets of plywood. Perhaps 1/4" thick.  Sand and round the edges so it doesn't abrade through the fabric. It would be a more permanent solution compared to new coroplast.

IanA Alberta Canada

[Mike Godwin]

Get a 6-pack of the thin plastic cutting boards, dollar store or other such place. They come in different weights. I use them in bags i make pushed into sleeves. 

Mike SLO CA 

[Joe Bernard]

Well I don't START with lots of stuff but I endeavor to be like Pam (Likes To Bike) and Leah (Bicycle Belle Ding Ding) who do everything on their bikes, so I go shopping and load it up! It sits on a Nitto rack and the stuff on the sides of the bag bend the coroplast down, maybe I should just pull the stiffener and let the rack do the work. 

[George Schick]

I don't want to hi-jack this thread, but having been inspired by the "lots of stuff" comment I decided to empty my saddle bag of its contents and weigh it.  2.55 lbs.  So I emptied it and went for an 8 mile round trip ride on the Ram to get some merchandize. The bike handled much better - more lively and a bit easer steering response.  Then I loaded it back up and weighed the merchandize when I got back home. 3.64 lbs.  On the return trip loaded up a noticed the difference right away.  I figure the extra ~lb. or so would be about what the bag contents weighs when I go for an extended ride with a cell phone, key ring, ID+some cash in a thin taxi wallet, and maybe a Clif Bar... so roughly the same weight.  Just sayin'.

[lconley]

You could try gluing two pieces of chloroplast together with the "grain" of the two pieces running at right angles, or three pieces at 60 deg - "plyplast"? 

This assumes that you are using free recycled signs.

Laing

[JohnS]

I'm with Ian, but instead of plywood, I use 1/8" fiberboard for bike bag stiffeners. Cut to size and coat with polyurethane to water proof it. Holds up great, downside is it's heavier than the plastic.

JohnS

[Mike Godwin]

John S

What is fiber board? Masonite? Chipped wood product?

Mike "who uses 2 x cardboard glued cross-grain for front basket base" SLO CA 

[George Schick]

Masonite is a brand name for fiberboard, AKA hardboard.

[Bill Lindsay]

Masonite is the stuff that lots of folks use as a top layer on a workbench.  Plywood provides the hardness, stiffness, strength and support.  Masonite is a smoother, splinter free, less absobant surface.  Masonite is a "consumable".  In a shop workbench, we'd replace the masonite top every couple of years.  On my home workbench, I've had the same masonite top for over a decade.  

Masonite itself is pretty weak, compared to other wood sheets.  Whether a masonite "stiffener" would be stronger or weaker than corroplast, I'd guess masonite would be somewhat stronger than corroplast, and somewhat heavier than corroplast.  

If there was a product that was much stronger than corroplast while being a similar weight, I would guess that there's probably a fiberglass sheet that you could buy at TAP Plastics.  (TAP Plastics has corroplast also).  I don't know how much it would cost, but it would not be free like campaign signs.  TAP Plastics is a very fun place to shop for things you didn't know that you couldn't live without.  

Bill Lindsay

El Cerrito, CA 

[Patrick Moore]

While I'd not want to use Masonite in my saddlebags -- too heavy; coroplast at right angles to pressure is better -- I do want to use it as a consumable workbench cover. Excellent idea that is new to me but which makes great sense. But first I'll have to clean up the work surface.

As to a bag stiffener: for me, the need is rather for something to absorb shocks of fragile items like wine bottles and cartons of eggs from jarring on the supporting rack; a 1/2" piece of dense foam works well.

Patrick Moore, who has a huge sheet of Masonite protecting the drywall behind his 6-bike bike hanging system on the East wall of his garage, and 1 or 2 left over corroplast signs left over from local elections in Farmington, NM 4 years ago, in ABQ, NM, and who is assiduously scrutinizing his Sugino cranks for trademark violations.

[Michael Baquerizo]

i bought a used sackville on ebay that didnt come with any stiffener. coroplast is pretty expensive at office supplies so i just used cardboard. i forgot if i doubled it up but i then wrapped it in gaffers tape for some rigidity. i originally tried to melt a plastic record sleeve on it so it'd stay water proof ish, but ditched that idea eventually. the biggest con is the only gaff tape i had was black which makes the inside of the sack seem like an abyss.

[JohnS]

Correct, Masonite/hardboard/fiberboard, I've also used it for a work bench top. It's held up well. I should say that I use the hardboard to replace the coroplast backing in a Sunlight shopping baskets that hang from the rear rack. So may not be applicable for the Saddle sack.

Here is the inside. The spring, from an old Cannondale pannier is mounted on the inside so that the bag rests flat against the rack.

Here is the back. The hooks are repurposed from a Wald basket.

JohnS

[Jay Lonner]

So the Surly TV Tray that I ordered earlier in the week arrived today — attached find some pictures. 

The first shows the TV Tray overlaying the coroplast from a large SaddleSack, and as you can see it’s a bit smaller all the way around, so maybe not as supportive if used inside the bag as direct replacement for the coroplast. 

The next two pictures are mockups using the TV Tray as an external support attached directly to a rear rack, and this approach looks a lot more promising (and is how I intended to use it all along). Much less sag, and eliminates the problem of smaller items working their way underneath the coroplast. I’ll see if I can’t wrap up final installation this weekend.

Jay Lonner

Bellingham, WA

Sent from my Atari 400

On Apr 19, 2023, at 6:04 PM, JohnS <shar...@gmail.com> wrote:

Correct, Masonite/hardboard/fiberboard, I've also used it for a work bench top. It's held up well. I should say that I use the hardboard to replace the coroplast backing in a Sunlight shopping baskets that hang from the rear rack. So may not be applicable for the Saddle sack.

Here is the inside. The spring, from an old Cannondale pannier is mounted on the inside so that the bag rests flat against the rack.

<Sunlight_Shopping_Bag_Inside_X.jpg>

Here is the back. The hooks are repurposed from a Wald basket.

<Sunlight_Shopping_Bag_back_X.jpg>

JohnS

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<Sunlight_Shopping_Bag_back_X.jpg>

<Sunlight_Shopping_Bag_Inside_X.jpg>

[Jacob t]

I solved this issue in my Fabios Chest by buying a storage bin lid at Target and cutting it down to size. Works great, and only cost a few dollars.

[Marc Irwin]

If you can't find an abandoned yard sign lying around, the big box hardware stores sell new pieces at pretty cheap prices.

Marc