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Cycle Truck

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I don't have a file with a half inch diameter, so I thought I'd try mitering on the lathe.  I also don't have a hole saw, so I did it with drill bits.  The tubing is secured in the lathe toolpost and I drilled the hole out to half an inch.
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I don't have a file with a half inch diameter, so I thought I'd try mitering on the lathe. I also don't have a hole saw, so I did it with drill bits. The tubing is secured in the lathe toolpost and I drilled the hole out to half an inch.

bicyclebrazingcargo bikecycle truckframebuildinglathemetalworkingrack

  • Untitled photo
  • Scribing the miter on the support bars.  I used a block of aluminum with a small hole punched in it as a gage.
  • The miter is partially rough cut on the grinding wheel.
  • The miter is tested on a piece of tubing
  • Two support bars mitered
  • Two support bars and their component pieces.  I am inserting tubes into the ends of each support bar to beef them up where the rack mounting bolts will pass through.
  • Rack mounting bolts inserted (but not yet brazed or filed flat)
  • I don't have a file with a half inch diameter, so I thought I'd try mitering on the lathe.  I also don't have a hole saw, so I did it with drill bits.  The tubing is secured in the lathe toolpost and I drilled the hole out to half an inch.
  • Final pass with the 1/2" drill bit.  It miters done this way were rough and required cleanup, I went back to just using a combo of a 12" round file and a 6" half-round file.
  • Bolt support insert brazed
  • Bolt support insert filed flush with the support bar
  • Everything dryfit to test.  There is the support bar, a pillow block (not really the right use of the term), and finally the rack tubing.
  • Another photo of the dry fit pieces.
  • Pillow block brazed onto the rack stay.
  • Rack perimeter bent and brazed.  It is 18" by 20".
  • The first couple cross pieces have been brazed into the rack
  • Rack platform is complete
  • Untitled photo
  • Bolt, support bar, pillow block, and rack
  • I'm making more pillow blocks.  The original ones weren't quite straight and I wanted taller ones with more thread engagement.
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