I ride bicycles. In a densely populated city like Jakarta where the traffic jams will never make sense, riding bicycle is the best way to go. Some might say riding bicycle in Jakarta's crazy traffic is insane, but let's keep that story for another time.
Owning a bicycle shop means sometimes I have to carry bicycle parts across town. In some cases, even frameset(s). While wheel(s) can be easily strapped to backpacks, messenger-style (providing it's big and versatile enough), carrying framesets or bicycles are another set of challenge. Resorting to motorcycles? While that sounds like a good idea, I still prefer carrying stuffs with bicycle because the running cost will be cheaper. And it's another way to advertise my small bicycle shop.
Enter the bakfiets. Or longjohns, as some may refer to it.
Two-wheeled cargo bike is preferred because while three-wheeled bikes could haul more stuffs, they did it by sacrificing the manuverability. I also go with front-loading because it's easier to manage in traffic, all with the low center of gravity and stuffs.
While three-wheeled cargo bikes are a bit more common in Indonesia, it's not the case with two-wheeled ones. Buying one from overseas will costs me a hell lot of fortune, all with shipping dimension and weight. So if one of the goals was to advertise my shop, why not building from scratch? In Jeremy Clarkson's words, how hard could it be?
So here's a not-so-well-written story about how I built my homebrew bakfiets. It's homebrew, because apart from the welding process (I don't have a welding machine in hand), I built it entirely on my home-slash-bicycle shop. Some language barriers might be found since English is not my primary language. I also didn't put much pictures of the process (only the results), since I didn't always have camera (or phone) in hand.

tl;dr, here's how I built my cargo bike!

Step 1: Design and Ingredients

The bakfiets was built from a steel donor bike with steel tubing extension on the front. Steel is chosen because of its price and availability, and also it's easier to work with.
Coming from a design background I figured some essential aspects regarding geometry. They are:

1. Fork trail.
Long story short, the trail length should be short to keep the steering stable yet agile enough. I didn't have the privilege of fabricating my own fork, so I have to modify a BMX fork (see "Ingredients"). Having good experience with touring bikes with 50-60mm of trails, I chose to run 51mm of trail on my design. Factoring this and the fork offset on the BMX fork, I got the headtube angle set at about 71,5 degrees. A bit slack.

2. Bottom bracket height.
To keep it stable on high and low speed, I make the bottom bracket height as low as possible. I ended up with about 289mm. You might want to get lower, but keep in mind that if you're using large rear wheel on your donor bike, a bottom bracket that's set too low will disrupt the riding position (the seattube angle will be too steep).

3. Wheelbase.
Imagine this bike as a bridge that suspended between the two wheels. You can go bananas by making the bike as long as possible, but you might ended up using bigger or thicker tubings to prevent the whole bike from sagging under heavy load.

Here's some of the ingredients I use for my bakfiets:
1. Steel mountain bike frame. A disc brake compatible model was chosen for extra stopping power. Derailer mount is a plus.
2. Steel BMX fork with 1 1/8" threadless steerer.
3. 16mm x 37mm square-section steel tubing, 2mm thick. I ended up using 9 meters of it.
4. I used 42mm steel pipes for the headtubes (front and rear) because they have internal diameter of 34mm, roughly the same as the outer diameter of 1 1/8" threadless headset cups. You might want to use thinner pipes for this purpose, as long as the internal diameter still be 34mm.
5. Some scrap 5mm steel plates or strips to make steering rod mounts and front brake caliper mounts.
6. I found an adjustable rod with heim joints from our local scrapyard, probably taken from a car or something. The heim joints are used for the steering rod.
7. 15mm steel rod, for the steering rod.
wow, very nice project! I never realised that a lot of none Dutch speaking people use the term bakfiets. bakfietsen are quite popular in the Netherlands though, I have a 3 wheeled one which can easily hold up to 100kg or 4 small children, I love it.<br>but making one yourself must be very satisfying and yours looks amazing.
thank you! it's very satisfying, not to mention the looks I got from people while riding this contraption.<br>but looks can be deceiving... after two years, I'm having an idea of redesigning this cargo bike with better material and refined manufacturing, since the material I recently used flexed quite a bit under loads over 70kg.
<p>hello there, i am about to start my own cargo bike project, i need though to buy a welding machine. so my question is, what did u use to do the welding? is it a MIG or a TIG welder? thank uou very muvh</p>
<p>In the pic where he is welding, he's using a &quot;stick&quot; welder. That's tough to do on thin tubing. I'm interested to know how it's holding up, especially the parts that he welded to the donor frame. I have limited welding experience. I wouldn't hesitate to weld those tubes with a mig welder and 0.024 wire, but would step up to a tig welder for anything that was connecting to the original donor frame.</p><p>Any updates on how it's holding up?</p>
affirmative! it's stick welded, simply because that's what my neighbourhood weld shop have.<br>have no trouble using them since the tubings are thick: 2 mm for the cargo structure, around 2mm on the cheap donor frame that I use.<br>got to admit, stick welding will give you messy result. they hold up just fine until now. but if I have to do it again (and I definitely will! stay tuned for the refined version), I will go with MIG, or better still, TIG weilding.<br>now to find MIG welder close to home..
<p>English is not your primary language, ie you are from a NESB, and &quot;stuffs&quot; isn't a word.</p><p>I don't yet know how to weld, and I don't know anybody who can weld for free for me, but maybe I can join a 'Men's Shed', although they probably don't have welding equipment for safety reasons.</p><p>So, how can I make my own bike?</p><p>Should I learn to make bamboo bikes?</p><p>Could I somehow clamp tubes together?</p><p>And/or I should just do most of the design and preparation work, then pay somebody to weld it?</p><p>What problems could there be if I didn't paint a steel bike?</p>
thank you for the grammar lessons! writing this whole Instructable in Bahasa Indonesia will be a lot easier for me, but maybe you will have quite a little bit help to comprehend it.<br>as for the bamboo cargo bike, browse around, you'll find a good Instructable about it: from which I take one or few inspirations. should you learn how to make bamboo bikes, or do design work and pay somebody else to do it? I don't know, should you?<br>steel will eventually rust. some people called it patina, but I for one can't stand having corroded tubing that will eventually weaken the structure of this heavy duty bike, so there's that.
no way you can buy a bakfiets for $500,- here in the netherlands. They are way expensive even more since they've become popular again. Nice job!
<p>Wouldn't bakfiets etc be cheaper when they are more popular?</p><p>Are the bakfiets made in China, or the Netherlands?</p><p>If made in China, then the price should be very cheap.</p><p>Can you buy bakfiets etc cheaply online from China eg Alibaba, Ebay, etc?</p><p>I have seen one company on Alibaba etc which says that they sell just 1 'Set'/piece/bike to customers, and for what seems to be a cheap price of about $500.</p>
Well yes and no, they are popular but still not sold in large numbers not like everyone has one. They start at around &euro;800 which is a $1000 and that easely doubles. <br><br>Importing one could be an option but with the expences for customs and importing it goes up fast.
<p>thanks! it only costs me that much because I got the steel tubing from the local scrapyard. most of the parts, including the rims, are parts I've already had kicking around in my parts bin. Shimano components are cheaper in Indonesia, that's a fact. and being able to build the wheel myself (and getting paid for doing it for other people) helps a lot. ;)</p>
I live in flat Palo Alto, and I love my bakfiets! I take both kids to daycare every day, including tons of stuff. Your bike looks great!
<p>thanks! the next thing on my list will be building a wooden cargo box with built in seats in it for my two children. it will definitely made the bike heavier, but my son already outgrown his bicycle child seat. the cargo box will let me carry both him and his little sister with ease!</p>
<p>sounds great! please post a picture when you're done...</p>
<p>this is on my list of things to build, possibly even this summer - do you (or anyone else?) have more info on the steering setup ? I can happily weld, but I'd like to know I'm welding in the right place :) </p>
<p>user carkat made a better written Instructable on the steering setup, here:</p><p><a href="http://www.instructables.com/id/build-a-2-wheel-cargo-bike/" rel="nofollow">http://www.instructables.com/id/build-a-2-wheel-ca...</a></p><p>good luck with your build!</p>
thanks :)
<p>it's stable enough for me, besides three wheels will make it harder to steer on tight traffic. it just takes time to get used to the handling, but it won't take you hours. I've got friends who already nailed complete U-turns on the first minutes aboard this bike. thanks by the way!</p>
如果有机会,我应该让你看看一种叫做&ldquo;倒骑驴&rdquo;的三轮自行车。 If you have a chance, I should let you see something called &quot;inverted donkey,&quot; the three bikes.
<p>thank you brother. it's stable enough in turns, just like riding a tandem if it's easier to imagine. a little wobble usually caused by the slack on the steering rod link, which I have to check periodically (about once every two months or so). I prefer two wheels because it allows me to lean harder in turns, making it agile. besides, with wheelbase this long, it's very stable on straight line.</p>
<p>Nice work! I've homebuilt a similar bakfiets style cargo bike &amp; love it, but my brakes are really bad.</p><p>Where did you get the disc brake front fork? Is there a brand / manufacturer on it? I can't find 20&quot; disk brake forks anywhere!</p>
<p>thanks! if you read the 4th step, you'll see that the fork is just an ordinary BMX fork with brake tabs brazed in place.</p><p>first I have the front disc and wheels installed on the fork dropouts, put the caliper on the disc rotor, and made a template for the caliper tabs with a cardboard. the template then transferred to 5mm steel plate, then brazed in place.</p>
Love it! Thank you so much for sharing your knowledge!
<p>Hats off and thumbs up to you an excellent build! I can see bike couriers in New York, Chicago or other large US cities or anywhere else where the terrain is relatively flat increasing their business with this type of vehicle. Keep up the good work.</p>
<p>great idea</p>
<p>I made it</p>
Super nice build!!
<p>I made it</p>
Very well done! Nice job!
Beautiful! I too live in bikehostile city, but could not live without my cargobike!

About This Instructable


522 favorites


More by ranggapanji: Another Homebrew Bakfiets (or Cargo Bike, if you don't speak Dutch)
Add instructable to: