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Cycle Truck

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bicyclebicyclesbrazingcargo bikecycle truck

  • To make the pillow block I drill 5/8" steel rod with a 1/2" drill bit on the lathe
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  • The hole is drilled.  I'll cut the bar in half at the center of the hole, making two pillow blocks.
  • One of the pillow blocks, rough
  • Drilling the 5mm hole axially in the block.  This will be used for the M6 mounting bolts.
  • Drilled and threaded for an M6 bolt.  The block is 10mm tall, giving 10 threads of engagement
  • Brazing the support bar to the frame.  I'll tack lightly first so that I can adjust everything to be square.  This joint aligns the entire rack.
  • Tacked and aligned
  • Support bar is brazed and the rack is mounted from the rear.  I didn't take any photos of brazing the front support bar.  I brazed the front pillow blocks to the rack and brazed the support bar to the frame all at the same time.  The rack was resting on the pillow blocks, the pillow blocks were bolted to the support bar, and the support bar was resting on the frame.  This kept everything in alignment, no fixtures necessary.
  • I switched the cable routing to run along the top tube so that none of the cables interfered with the rack.  Here I'm brazing on the cable housing stop for the front derailleur.  I copied this brazeon clamp fixture from Alistair Spence.
  • The rack is done and mounted.  The cable routing has also been moved to the top tube.
  • Front end view
  • Test riding with ~40lb load (a 3.3 gallon keg full of water)
  • I rode over to the Bike Shack carrying a donor bike (we stripped it for parts there) and a bag for my other errands.  Cars gave me wide berth with this big load.
  • Heading out to run errands.  The rack dwards my large Timbuk2 bag.  In the background you can see Lee's Pugsley porteur.
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