DIY bicycle trailer

Step 2 Build the trailer bed

This step is not difficult but the devil is in the details. If you do not have a router then you will need a hand held jig saw or a wood bit for your drill and a keyhole saw unless you have u-bolts that extend more than 1-3/8", in which case you will only need a drill.

If you are using the firewood cart axle and wheels I decided to use then cut two pieces of 1/2" plywood 21"s wide and approximately 32" long. You can go longer but the idea here is that all of the weight will be centered as close to the axle as you can get. The three bags of cement (90lbs per bag) or eight concrete block (30 to 40lbs per block) per load or 240 to 320 lbs per load I will be trailering will stack nicely in this amount of space.

If your u-bolts are long enough then merely locate the center of the length of the plywood you cut and drill the holes for the 1/2" u-bolt there with holes for the 3/4" u-bolts about 3 inches from the sides. If your u-bolts are not long enough then either make cutouts in one sheet of plywood as recesses for the u-bolts, span washer and nuts or use a router after the pieces are glued to make the receses.

To build up the trailer bed merely use construction adhesive and drywall screws to hold the two pieces of 21" x" 32" 1/2" plywood you cut together.