Having bought my BMW R1200GS new in Anchorage, and didn't want (nor could really afford) a set of Jessies. I heard horror stories about breaking the standard BMW panniers later, and as I am on the road to Argentina figured I should stop somewhere and relieve myself of the worry. Here's what I came up with, I made them in a muffler shop in Oaxaca, Mex. I have dropped the bike once and there was no damage to the bags or the guards.
They are made of 3/4شاط?© x 16g mild steel tube, using 5/8شاط?© solid internally where I needed the tube to slide on and off شاô refer photos below.