StuffBoxx is an ingenious packing solution for adventure riding. It keeps stuff neat and organized inside the pannier, and prevents rub marks or abrasion of your gear.
StuffBoxx is constructed from a durable black plastic, with gently rounded corners, a hidden lifetime hinge, and a snap-close lid. Unlike common household plastic storage containers, there’s no lip or rim to waste space. StuffBoxxesä nest together perfectly.
Dimensions are 4.5″ deep x 6.5″ long x 8.5″ high. That size is just right to hold a CyclePump, an EZAir gauge, a Stop&Go Pocket Plugger, and a few tire repair items. We use another StuffBoxx for our roadside maintenance tools, another holds our cooking gear, another our camera, etc.
Organization is the key to successful adventure packing, and the StuffBoxx provides the foundation to achieve that goal. It all comes down to a series of small containers that store neatly within the pannier itself. Each container is clearly marked with the contents, and each container stays inside the pannier until it’s needed. No sense pulling everything out or digging to the bottom of a pannier or bag liner just to get at one tool.
Here’s pair of StuffBoxxes next to our 38L Metal Mule panniers. We can easily fit 8 of ’em inside.
These next photos show how we arrange our StuffBoxxes. Any extra space we fill with odds and ends. We maximize every cubic inch. How you arrange the boxes depends on your gear, and the dimensions of your panniers.
Cordura bag liners may seem like a good idea (at first), but in practical application they may not be your best option. As you ride the road or trail, your gear is always bouncing and rubbing against other gear (or against the side of the pannier). If you have un-anodized panniers, gear turns black from contact with the aluminum. Even when your gear is inside a liner it can still get damaged. Sure, liners are handy if you want to take the entire contents of your pannier inside the motel at night, but for us the StuffBoxxes work best. We take only what we need. When we need everything, we just take the whole pannier – with a Metal Mule quick release system that’s easy.
When we rode to Alaska and along the Continental Divide, we had a series of Stuffboxxes in each pannier. We knew exactly where everything was stored. We could quickly put our hands on what we wanted, when we wanted it. The top was labelled with the exact contents of each box, so there was no guessing where we’d stored that spare alternator belt or replacement taillight bulb. (It’s frustrating when you know you have a certain tool, but can’t remember where you stored it… this only gets worse as you get older!) Properly marked StuffBoxxesä solve that problem. Every StuffBoxx comes with a weatherproof label on the lid, so you can list the contents.
Here’s a photo of our CyclePump in a StuffBoxx. Another photo shows the hinged lid.
World traveller Mike Paull reports that a StuffBoxx is THE BEST solution he’s found for carrying spare inner tubes. Every other method resulted in chafing at the corners where the tubes were folded. Those chafe marks quickly tranformed into a flat tire when the tube was mounted. Mike also uses StuffBoxxesä for breakables and other small parts and pieces.
Thanks to Steve Irby for coming up with the idea for the StuffBoxx. This photo shows how he arranges his gear inside his pannier. Steve uses a labelmaker instead of our printed content labels. We call him Mr. Organized.
Packing hint 1: Small nubs on the lid on the StuffBoxx engage small indents on the inside rim of the box. These tabs keep the lid closed for most applications. But when we’re expecting really rough conditions, or when we’re packing the box on its side, or upside-down, we use a small piece of gaffer tape to seal the lid even more securely.
Packing hint 2: When we’ve got a series of StuffBoxxes snuggled tightly inside the pannier, we create a small tab from a piece of gaffer tape. We stick the tape to the side of the box and let the tab stick up like a flag. When we need to pull out the box, we grab the flag and pull up the box.