[erob123]

Help guys got the rattle.  Never thought. But guess so.
Eric

[ace.cafe]

A little bit of self-adhesive foam weatherstripping applied judiciously to the proper spots on the inside of the pannier frames should do the trick.

Should be available at any hardware store or Lowe's, Home Depot, etc.

[sqf]

I took 3/8 black coolant hose and chopped it up into 1" sections.  Then split it down the side and put it over the pannier bars in the appropriate locations, no more rattle!  Next project is to use auto undercoating on the inside to make them water resistant.  My tools and everything get wet each time I ride in the rain. 

[edthetermite]

The military has some additional issues the other models don't have.

The panniers are a sore spot on the military. Mine already had the latching hasps break off. The rattle problem was solved with some old inner tube sandwiched between the frame and box.

To me the manufacturer (our Indian friends) is dropping the ball on the panniers. They are not very well constructed. Lid to box fit is kinda a joke. Customers shouldn't have to retrofit the panniers to make them work.

I have a bungee cord on mine until I decide what lid fastenng system to go with.

To the factory I would also suggest that you don't put shiny silver exhaust pipes on an all green military bike. Duh.

Ed

[erob123]

Right On!  A Black Cherry Bomb would look good.

[LotusSevenMan]

The little gold coloured overcentre cupboard catches @ about 2.20ukp a pair with some single sided foam stuck over the inner lip of the panniers (and some of this foam in between the pannier frame and boxes in strategic places) solved all the rattles on mine!