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Cargo Bike

A front load light duty cargo bike. I used a donor Trek 800 frame (late 80s) for the rear triangle and a built a new front triangle designed for a 20" front wheel. This is my first bicycle frame (partial or full).
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alignment tablebicyclebrazingcargo bikeframe fixtureframe jig

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  • Scribing the lines for the miter of the rack sub-structure to the frame.  The square tubing is 5/8" high and the cargo tube has a 7/8" radius.  I put a punch mark in a piece of aluminum 1/2" (4/8") from the edge and used that as the center of my compass.  With the square bar placed next to it I got a 3/8" tall arc of the correct radius, leaving 2/8" (1/4") to stick up above the cargo tube.
  • I roughed out the miter using a grinding wheel.  I actually went back and removed a bit more metal with the wheel after taking this photo.
  • Testing the final miter against a piece of scrap (one of my test pieces from trying out the cargo tube/head tube braze).
  • Two identical miters cut, one in each of the support tubes.
  • I drilled 5/16" holes for the bolts that the rack will mount to.  There will be 5/16" x 0.035" support sleeves brazed inside.<br />
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I also used the mill to square up the ends of the tubes and make sure that they are perfectly centered with each other.
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