Bicycle cargo trailer--200 lb capacity, $30 for parts

Step 3 Fabrication of the parts: Main frame

From the first piece of 1/2" EMT (10' long)

*This piece will be the main frame. With all tubes, make all marks before bending.

*Mark at all the following lengths from one end before bending. Make a small star symbol at the starting end to signify start bending from this side. Mark at 2", 41", 61", and 100".

*Make a dotted line at 118". This will be the mark to which the tube overlaps when it is bent into a rectangle. Eventually, the last 2 inches will be cut off, but the tube is bent with the 2 inches to allow adjustment if the bends are uneven.

*Bend 4 bends to make rectangular shape. With each bend, make sure that the previous bend is in the same plane. Line it up by eye, and fix mistakes by hand.

*Holding the two ends of the tube in overlap of 2", measure the width of the frame at the front and back, before the bends. It should be around 22" or 22 1/2". If the front and back are unequal distances, you can cut off more or less than 2" from the end of the tube. Cut approximately 2" off the end of the tube. Bend the frame by hand so that the two mating tubes are in line with each other.