- Copy the template from the sketch (1 cm squares) (Photo 1). For a single
corner, you can use thick paper or cardboard; if you want make more, a
piece of thin aluminium or zinc is better.
Photo 1. Template.
- Make a mould from a piece of (hard) wood, thick 23 mm and 65 mm wide;
slightly round the corners. Drill 3.1 mm holes as can be seen on the
pictures, corresponding with the holes in the steel reinforcing corners.
Also make at least 4 steel pins fitting the holes; 3 mm welding rod will
do. (Photo 2)
Photo 2. Hardwood mold.
- Find some saddle leather, 2 - 3 mm thick; black or brown will do.
Be careful with old leather from briefcases etc..; it will easily tear
- Cut the leather according to the template; there is a difference
between the left and the right corner ones! Punch out the 4 holes with
a 3 mm hollow punch. (Photo 3)
Photo 3. Cut and punch leather pieces.
- Soak the leather for 24 hrs in water.
- Insert two pins in the mould, put the leather on these pins, and
fold around the mould. Then, insert the two other pins. With 3 mm
leather this will require some persuasion! (See photo 2).
- Let the leather dry for 24 hrs; do NOT use heat.
- Now put the corner in place, temporarily fixing it with 3 mm
screws and with the steel reinforcing corners in place. (Photos 5 and 6).
If you don't have these corners, you will have to make them of thin
(0.8 - 1 mm) sheet steel, and treat them with any anti-rust product;
I used zinc coating from a rattle can. (Photo 10)
- Put the bag on the frame, and mark the place of the press fastener
using a small hammer. (Photo 7). Remove the corner, and put in a press
fastener; if you don't have the tools for that, go and see your
- Attach the corner again with the 3 mm screws, and using 3mm flat
head copper rivets and washers, replace one by one the 3 mm screws
If the rivets are too long, cut them off at about 2 mm above
the washer. Avoid the normal hollow rivets; they will not withstand
the rough life on a M20 bike, unless they are of the stainless steel
variety (photo 9).
Photo 9. Rivets.
- Use a split rivet to fix the small corner flap.
- Now finish with some leather oil or wax.