If you need to transport heavy cargo with your bike you can build a tough trailer

like the one I helped to build in Piubici (http://www.piubici.org/) for the Bricheco
(http://bricheco.wordpress.com/) girl.
You only need a pair of small bicycle wheels and some steel profiles, and of
course a basic welding know-how.
(http://cdn.instructables.com/F4A/164P/HYC655LG/F4A164PHYC655LG.LARGE.jpg)
About This Instructable
License:
27,075 views
240 favorites
andrea biffi
(/member/andrea+biffi/)
(/)
let's make
share what you make >
(/editInstructable/)
(/)
Explore (/tag/type-id/) Create (/about/submit.jsp) Contests (/contest/) Community (/community/) Login (/account/login) | Sign Up (/account/gopro?sourcea=header)

Digi-Key
Electronics
digikey.com
Same Day Shipping Til 8:00 PM CT. Order
Now at DigiKey.com!
Champion
Window Ofcial
Remove these ads by Signing Up (/account/gopro?
sourcea=removeads&nxtPgName=Bicycle+trailer+for+heavy+cargo&nxtPg=/id/Bicycle-trailer-for-heavy-cargo/?ALLSTEPS)
Step 1: Frame material
Recommendations
(http://cdn.instructables.com/FLL/3A27/HY5NWTXC/FLL3A27HY5NWTXC.LARGE.jpg)
(/member/andrea+biffi/)
www.andreabiffi.com
(http://www.andreabiffi.com)
Follow
I'm an Italian freelance structural
engineer, graphic designer and
photographer. I'm also investigating
electronics, robotics and science in
general. I enjoy hacking and disassembling
as much as desig...read more
(/member/andrea+biffi/)
1534
Bio:
(/id/small-foldable-tripod-
dolly)
(/id/the-stem-lamp)
(/id/biga-the-bike-trailer)
More by andrea biffi
Bicycle trailer for heavy cargo (/tag/type-
id/category-outside/keyword-bicycle trailer for
heavy cargo/)
bicycle (/tag/type-id/category-outside/keyword-
bicycle/)
trailer (/tag/type-id/category-outside/keyword-
trailer/)
welding (/tag/type-id/category-outside/keyword-
welding/)
bike (/tag/type-id/category-outside/keyword-bike/)
heavy (/tag/type-id/category-outside/keyword-
heavy/)
box (/tag/type-id/category-outside/keyword-box/)
wood (/tag/type-id/category-outside/keyword-
wood/)
custom (/tag/type-id/category-outside/keyword-
custom/)
diy (/tag/type-id/category-outside/keyword-diy/)
Tags:
To obtain cool and easy to weld steel bars I suggest you to look for a used old
bed frame. Since in last years people love to sleep on wood staves, you
probably will not have any difficulty to find those metal frames. And of course
you will keep the springs for your next project (actually you need one for the
hinge)!
Step 2: A sketch of the project
(http://cdn.instructables.com/F7A/BH0F/HY5NWU01/F7ABH0FHY5NWU01.LARGE.jpg)
(http://cdn.instructables.com/FG7/T0TI/HY5NWU47/FG7T0TIHY5NWU47.LARGE.jpg)
Beautiful acetone
lamp from reused
The Remote Match
Mistick - as in Mist
Stick!
Every Day Carry
(EDC) Book
LED Nametag Real Life Super
Mario Concrete
Slicing with 123D
Make
Levitating Acrylic &
Whiteboard Coffee
You can see that this trailer frame has been designed to match the wood box
dimensions. Anyway you can go through the inverse process, build a frame you
like, then make a box with the right dimensions.
Draw a fast sketch, and note all the measures you need. This is very important
to avoid mistakes. Notice that I used the bed corners to become the trailer
corners, that is very useful since you will need to only weld straight pieces.
Then ,using a grinding machine, cut the bed frame in the pieces you need. Try
to make straight cuts and to keep the blade orthogonal to the bar, to do that help
yourself with paper tape.. After cut a piece mark it with paper tape to recognize
it. place crossed pieces of tape to mark remains.
Step 3: Refining
(http://cdn.instructables.com/FH6/WH9N/HY5NWU9O/FH6WH9NHY5NWU9O.LARGE.jpg)
(http://cdn.instructables.com/FVI/TFY3/HY5NWU64/FVITFY3HY5NWU64.LARGE.jpg)
(http://cdn.instructables.com/FED/UVW5/HY5NWUEI/FEDUVW5HY5NWUEI.LARGE.jpg)
Having all the pieces cut, place them all together, referring to your project. All
pieces have to touch one each-other almost perfectly. The more the lengths are
precise the more will be easy to weld them. If you find out that a bar is too long
change the blade of the grinder and with the thicker blade smooth and shorten
the bars.
Now with the same grinder blade remove all the painting around the extremities
of all the bars, and also on the surfaces corresponding to the welding points.
You cannot weld on the paint.
Step 4: Welding
(http://cdn.instructables.com/FUN/1TQ4/HY5NWUHD/FUN1TQ4HY5NWUHD.LARGE.jpg)
(http://cdn.instructables.com/FHU/BNDP/HY5NWULO/FHUBNDPHY5NWULO.LARGE.jpg)
(http://cdn.instructables.com/F69/KWYP/HY5NWUN9/F69KWYPHY5NWUN9.LARGE.jpg)
Place all the pieces on a flat surface, and safe to welding. Then measure all
dimensions and also diagonals to be sure that the frame parts are exactly in the
right position, as previously decided in the design.
Be careful since the first weld joints will pull the metal and change the angles.
You can adjust the angles pulling and pushing the welded pieces, then continue
the work with the edge pieces. Then you can wedge the other parts in, so to
weld them very handy.
To make a perfect welding
(http://en.wikipedia.org/wiki/Shielded_metal_arc_welding) the best way is to
have a good teacher (http://roccosaldailmondo.blogspot.it/) ;-) anyway there are
a few rules to follow.
Try to not use a thick electrode, usually these tubes have a very thin surface
and it's very common make an hole while welding with 2 mm or bigger
electrodes.
Another way to avoid holes is to interrupt the arc every about half second,
wait the same time, and make contact again, in that way you can regulate
the temperature of the fluid metal.
If an hole appears you can close it, but it's not easy and it takes a lot of time
(and material) so be careful to avoid holes.
I found very difficult starting to weld with a new electrode, to avoid mistakes
start a new electrode on a test surface.
If you have to weld thick metal pieces, like dropouts, increase the amperage,
compared to welding two thin layers.
Avoid looking at the spark, always use good welding glasses or helmet, there
are very handy Auto Darkening Solar Welding Helmets
(http://www.ebay.com/sch/i.html?
_sacat=0&_from=R40&_nkw=Auto+Darkening+Solar+Welding+Helmet&_so
p=12).
Wear appropriate dresses: non-flammable gloves and coverall.
ALWAYS ASK TO SOMEONE EXPERT TO LEARN HOW TO WELDING, HIGH
CURRENTS ARE VERY DANGEROUS!
Step 5: Dropouts
(http://cdn.instructables.com/F47/H1T3/HY5NWUP4/F47H1T3HY5NWUP4.LARGE.jpg)
You can make the dropouts from a thick steel par. Follow the schematic to
understand the process steps.
At first cut four holes at the same distances (about 4 - 5 cm) then cut at half
distance between them, and finally with the grinder cutting blade remove the
metal pieces to open the little forks.
After the cutting process, place all the dropouts together in a big vise, and refine
them so that they all have the same shape.
(http://cdn.instructables.com/F5G/PKDR/HY5NX4PD/F5GPKDRHY5NX4PD.LARGE.jpg)
(http://cdn.instructables.com/F1M/PSC6/HY5NWUWP/F1MPSC6HY5NWUWP.LARGE.jpg)
Step 6: Place the dropouts
(http://cdn.instructables.com/FS3/EA3Y/HY5NX4MY/FS3EA3YHY5NX4MY.LARGE.jpg)
(http://cdn.instructables.com/FUK/7KPN/HY5NX4LY/FUK7KPNHY5NX4LY.LARGE.jpg)
The dropouts have to stay aligned together and with the frame orientation, while
soldering. The best way to do that is to squeeze them between nuts along a
threaded metal bar, possibly with the same diameter of the wheels bar.
The distance between the dropouts depends on the wheels you wish to use. In
my case is abut 9-9.5 cm. Use 10 cm if you want to use 26" wheels.
Step 7: Weld dropouts
Also in this occasion the first welding joints will pull the metal, so be careful to
keep the bar strongly connected to the frame. Weld the dropouts and complete
all the welding process. Now you can remove the threaded bar and check that
the wheels fit well.
Don't follow my example about the dress, remember, non-flammable gloves and
coverall!
(http://cdn.instructables.com/FYF/SURO/HY5NWV0T/FYFSUROHY5NWV0T.LARGE.jpg)
(http://cdn.instructables.com/FYF/TZCH/HY5NWURJ/FYFTZCHHY5NWURJ.LARGE.jpg)
(http://cdn.instructables.com/FSR/EMKU/HY5NWUYK/FSREMKUHY5NWUYK.LARGE.jpg)
(http://cdn.instructables.com/FGM/T7DY/HY5NWUTD/FGMT7DYHY5NWUTD.LARGE.jpg)
Step 8: Wood box
The wood box is not difficult to build. In this case we added metal profiles to
protect the wood edges.
Step 9: Mini-wheels
(http://cdn.instructables.com/FDA/FRFI/HY5NWV2E/FDAFRFIHY5NWV2E.LARGE.jpg)
(http://cdn.instructables.com/FLT/WH2W/HY5NWV41/FLTWH2WHY5NWV41.LARGE.jpg)
Four mini-wheels will be very useful in two ways. They act as locker to keep the
box steady on the metal frame, and they will let you moving the box when you
take it off from the trailer.
It's very important that you secure the wheels in the right position with strong
screws. To determine the exact positions flip the box upside-down, flip the frame
too, and place it on the box. As you can see in red in the drawing the four
corners are very good places where to screw the mini-wheels.
Step 10: The hinge
(http://cdn.instructables.com/FJK/TQTU/HY5NWV6U/FJKTQTUHY5NWV6U.LARGE.jpg)
(http://cdn.instructables.com/FIK/O7NN/HY9Y6HKY/FIKO7NNHY9Y6HKY.LARGE.jpg)
The hinge has to be very strong, to avoid to lose the cargo on the street. A good
way is to use two chain rings, gripped in two pieces of metal pipe.
The long bar soldered at the pipe extremity will keep the hinge firm when
attached to the bike axle.
To avoid that chain makes a bothersome clacking with the bike movement you
can add a spring (one from the bed frame) which keeps the two rings in contact.
Step 11: Load it up!
(http://cdn.instructables.com/F5P/PQ91/HY5NWV8K/F5PPQ91HY5NWV8K.LARGE.jpg)
(http://cdn.instructables.com/FU6/WI4J/HY5NWVEG/FU6WI4JHY5NWVEG.LARGE.jpg)
(http://cdn.instructables.com/FEI/OMQ3/HY5NWVCB/FEIOMQ3HY5NWVCB.LARGE.jpg)
Now place the wood box on the frame and load it to test the strength and
stability. As you can see in the cover picture you can also carry a person if you
wish! Enjoy!
Step 12: UPDATES
(http://cdn.instructables.com/FTU/JU0G/HY5NWVG9/FTUJU0GHY5NWVG9.LARGE.jpg)
(http://cdn.instructables.com/FT4/8LUV/HY5NX4NT/FT48LUVHY5NX4NT.LARGE.jpg)
(http://cdn.instructables.com/FK8/1PC3/HY5NX4OK/FK81PC3HY5NX4OK.LARGE.jpg)
I still have a few updates to do. As you can see I drilled some holes in the wood
panels, so to use them as handles.
Then I glued and screwed a red wood profile all around the edge, the wood
container now is more nice-looking in my opinion.
(http://cdn.instructables.com/F43/QMRD/HYC6CTNG/F43QMRDHYC6CTNG.LARGE.jpg)
(http://cdn.instructables.com/FMJ/K3DB/HYC6CTN7/FMJK3DBHYC6CTN7.LARGE.jpg)
(http://cdn.instructables.com/F9H/1A0P/HYC6CTMO/F9H1A0PHYC6CTMO.LARGE.jpg)
Make Comment
(/member/hunter999/)
6 hours ago Reply (C3C3NS1HYE5UOPO)
(/member/Bujholm/)
10 hours ago Reply (C90CKZFHYEAPA7X)
(/member/effgee/)
12 hours ago Reply (C0Q1NACHYC6H3GQ)
(/member/Bujholm/)
10 hours ago Reply (CZSZ4KEHYEAPA23)
(/member/andrea+biffi/)
12 hours ago Reply (CYWHU19HYE5TMAY)
Add also a bicycle tube around the bar soldered to the hinge to avoid ruin the
bicycle frame paint.
The metal frame has been covered with a special paint to protect it from rust,
and we have to paint it with a red colour. Next thing to make is also a good
fastening handy to lock and unlock, for the wood box, and rubber foot to avoid
clanking against the trailer. So... stay tuned!
hunter999 (/member/hunter999/)
Heavy cargo indeed :D Great job done here, clear instructions too! :-)
Bujholm (/member/Bujholm/)
great job, this trailer. When I saw your first (the one out of bike parts) I wondered
what exactly can be towed on it since the platform seemed to be quite small. But
that one is great - platform big enough and well balanced, and with a removable
box! Good idea - it can be replaced with a flat platform for example to tow
someting long. Or with a more elaborate box with cutouts for the wheels and
sticking out in all directions :)
One thing that makes me think when I consider building one of these is how to find
the balance between the weight of the thing itself and the carrying capacity - you
know, a lighter structure will fold under 100 kg, and a sturdier one weighs 100 kg
on its own, all to be hauled by yourself.. Time to learn to weld aluminum, maybe.
effgee (/member/effgee/)
always a good idea to weak thick leather gloves and long (non-flammible) pants
when welding - I imagine you ended up with some nice burns on your exposed
skin from this session
Bujholm (/member/Bujholm/) effgee
seems like everybody who has ever welded feels inclined to comment on
these photos :) Mine is further..
andrea biffi (/member/andrea+biffi/) (author) effgee
No burns this time, I didn't
weld the entire frame, but you
are undoubtedly right, I will
organize better next time.
(http://cdn.instructables.com/FGW/KMPX/HYC6CTN2/FGWKMPXHYC6CTN2.LARGE.jpg)
(/member/eatteyah/)
12 hours ago Reply (CNEZYP9HYEAP6M0)
(/member/andrea+biffi/)
12 hours ago Reply (CVOTTVHHYE5TMYS)
(/member/lindarose92/)
21 hours ago Reply (CV1A44BHYE5S5RU)
(/member/andrea+biffi/)
12 hours ago Reply (C6RRGXVHYE5TMQE)
(/member/Bujholm/)
21 hours ago Reply (C4NAXL3HYEAM2S5)
(/member/srilyk/)
17 hours ago Reply (CRFYSTDHYE5SKS6)
(/member/andrea+biffi/)
12 hours ago Reply (CPWNDHVHYE5TMOB)
(/member/blissful2015/)
12 hours ago Reply (C4B765MHYC6GXNK)
eatteyah (/member/eatteyah/)
WOOOOOW Very Good , Need Some paints and finishings
andrea biffi (/member/andrea+biffi/) (author) eatteyah
Yes, still to be painted, almost
certainly with a red colour. We
are working on it :)
lindarose92 (/member/lindarose92/)
That looks like a lot of work, great job!
andrea biffi (/member/andrea+biffi/) (author) lindarose92
grazie! :)
Bujholm (/member/Bujholm/)
Gosh, I don't know how you can weld in shorts like this, and wearing your mask in
a bare hand. The first time a tiny ball of molten metal burned through my skin I
have learned to wear full cotton overalls in the hottest of weathers, even though it
sucks in times of summer like right now. I am not even talking about UV exposure
which is not to be sneezed at either. Or are you using some welding tools that
neither spit metal nor emit hard UV?
srilyk (/member/srilyk/) Bujholm
I've heard of people who've gotten flash burns, but I (not the OP) have
never had any. I wonder if you're less likely to get UV flashes when
welding thinner metals - mine is a simple Harbor Freight 80 Amp buzz
box.
andrea biffi (/member/andrea+biffi/) (author) srilyk
I don't know about UV but
undoubtedly with thin
electrodes and low amperage
the sparks are not terrible.
Anyway an appropriate dress
is really suggested, I should
add it in the tutorial.
blissful2015 (/member/blissful2015/)
this looks like so much fun and you have a really nice workshop andrea! i
would love to be the 'heavy cargo'!
andrea biffi (/member/andrea+biffi/) (author) blissful2015
(/member/andrea+biffi/)
12 hours ago Reply (CK6BI8OHYE5TMCP)
(/member/andrea+biffi/)
12 hours ago Reply (C5G7S1THYE5TMBX)
(/member/fred1968/)
yesterday Reply (CTVVF33HYE5RL40)
(/member/noahl/)
yesterday Reply (CONCHMWHYEAKR6Z)
(/member/andrea+biffi/)
yesterday Reply (COTS9HHHYC6CKF6)
(/member/Snidely70448/)
yesterday Reply (CU1XC7OHYC6C6AD)
(/member/andrea+biffi/)
yesterday Reply (CEK88MVHYC6CKEJ)
The workshop is the Piubici (http://www.piubici.org/) laboratory!
Yeah a lot of fun, can't wait to make a new trailer/bike frame!
andrea biffi (/member/andrea+biffi/) (author) blissful2015
The workshop is the Piubici
(http://www.piubici.org/)
laboratory!
Yeah a lot of fun, can't wait to
make a new trailer/bike frame!
fred1968 (/member/fred1968/)
For a quick disconnect, you could have use this rapid link instead of the chain ring.
Nice work !
(http://cdn.instructables.com/FFZ/8L23/HYE5RL1S/FFZ8L23HYE5RL1S.LARGE.jpg)
noahl (/member/noahl/)
Great job, with very clear instructions! I built a similar trailer, and have one point to
add: consider offsetting the wheels towards the back of the trailer. If the load is
centered behind the trailer wheels, bumpy streets will apply upwards force on the
rear wheel of the bike, making for very strange bike handling. If the load is
between the rear bike wheel and the trailer wheels, it is much more comfortable.
andrea biffi (/member/andrea+biffi/) (author) noahl
thanks, I'll take it into account for
next trailer (more will come!)
Snidely70448 (/member/Snidely70448/)
Hardcore! Welding in that outfit, you must really be into pain!
andrea biffi (/member/andrea+biffi/) (author) Snidely70448
LOL! We are lucky since this july
has been rainy and fresh in north
Italy, but it's very humid, so it's a
pleasure stay with no t-shirt. I
didn't have accidents with
incendescent sparks (not yet) ;-)
(/member/KEUrban/)
2 days ago Reply (CVV6LB9HYCSWCUP)
(/member/andrea+biffi/)
yesterday Reply (CB324AOHYCSY2C7)
(/member/jmwells/)
2 days ago Reply (CO24U57HYC5YSLD)
(/member/andrea+biffi/)
2 days ago Reply (CMXULNRHYC60DCD)
(/member/LynxSys/)
yesterday Reply (C2HBA1AHYCSWRWG)
KEUrban (/member/KEUrban/)
Andrea, nice technique for ensuring the dropouts are all correctly aligned.
Ingenious.
andrea biffi (/member/andrea+biffi/) (author) KEUrban
it's Rocco's idea! look at his blog
(http://roccosaldailmondo.blogspot.it/)!
jmwells (/member/jmwells/)
Nice. I would consider adding handles to the box. Easier to load/unload
to/from the frame. Easier to control when using the casters. A box top would
give you more cargo space, tho more of a chance of overloading.
andrea biffi (/member/andrea+biffi/) (author) jmwells
Yes! We are improving the box,
so I will update the insructable
very soon, stay tuned! ;-)
LynxSys (/member/LynxSys/) andrea biffi
For simplicity and strength, you
could add some cutouts to act as
handles using a router.
About Us
Who We Are (/about/)
Advertise (/advertise/)
Contact (/about/contact.jsp)
Jobs (/community/Positions-available-at-Instructables/)
Help (/community?categoryGroup=Help)
Find Us
Facebook (http://www.facebook.com/instructables)
Youtube (http://www.youtube.com/user/instructablestv)
Twitter (http://www.twitter.com/instructables)
Pinterest (http://www.pinterest.com/instructables)
Google+ (https://plus.google.com/+instructables)
Tumblr (http://instructables.tumblr.com)
Join our newsletter:
Terms of Service (http://usa.autodesk.com/adsk/servlet/item?siteID=123112&id=21959721) |
Privacy Statement (http://usa.autodesk.com/adsk/servlet/item?siteID=123112&id=21292079) |
Legal Notices & Trademarks (http://usa.autodesk.com/legal-notices-trademarks/) | Mobile Site (http://m.instructables.com)
(http://usa.autodesk.com/adsk/servlet/pc/index?id=20781545&siteID=123112)
Join!
2014 Autodesk, Inc.
English enter email
Resources
For Teachers (/teachers/)
Artists in Residence (/group/air/)
Gift Pro Account (/account/give?sourcea=footer)
Forums (/community/)
Answers (/tag/type-question/?sort=RECENT)
Sitemap (/sitemap/)
Go Pro Today (/account/gopro?sourcea=footer)
We're Hiring! (/community/Positions-available-at-Instructables/)
Mobile
Download our new apps for iOS,
Android and Windows 8!
Android
(https://play.google.com/store/apps/details?
id=com.adsk.instructables)
iOS
(https://itunes.apple.com/app/instructables/id586765571)
Windows
(http://apps.microsoft.com/windows/en-
us/app/7afc8194-c771-441a-9590-
54250d6a8300)
(http://www.pinterest.com/pin/create/button/?
url=http%3A%2F%2Fwww.instructables.com%2Fid%2FBicycle-
trailer-
for-
heavy-
cargo%2F%3FALLSTEPS&media=http%3A%2F%2Fcdn.instructables.com%2FFGW%2FKMPX%2FHYC6CTN2%2FFGWKMPXHYC6CTN2.MEDIUM.jpg&guid=1XvqZP72X84n-
0&description=carretto33.jpg)