I just took apart my sport panniers, in preparation to paint them. It was a bit 'fiddly' figuring out how they come apart, but overall it was quite simple. Here are the steps:
1. Inside of the case there are two small torx bolts that appear to be holding the lid string stays in place. Remove both of these, they have nothing to do with the strings, and they actually hold the black plastic case protectors in place. Take care with the small parts, as there is also a metal insert, in the lid that the bolt goes through, that will be loose.
2. Once the bolts are removed, the black plastic case protector can be swung out of the way, exposing the inner hinge. There are four phillips screws in the inner hinge crevice, remove them. On the left pannier all 4 are located in the hinge cavity. On the right hand pannier, three are in the hinge area, one smaller screw is inside the case. Unsnap the string stays from the inner case, now the entire lid and the black plastic protectors can be removed as an assembly.
3. The black case protectors can be separated from the lid by separating the two hinges. The grey lids hinge is just a portion of the metal rod that the lid uses for strength. It takes a little bit of manipulation to separate the rod from the black case protector hinge, but once they are apart, you are done.
Here is a pic of the case protectors, swung out of the way, once the top/lid portion of the panniers has been removed:
Now you have just the grey lid portion, ready for painting. The expandable vinyl portion does not appear to come off, and looks to be sewn on. This will have to be masked off, unless you plan on painting it as well (with vinyl dye or similar).
I am going to use a black satin plastic fusion paint on mine. I am undecided as to whether or not I am going to dye the vinyl expansion portion black or not, so I am looking for opinions? Thanks.