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Step 4Cable mount, vibration absorber
This took me some thinking. Springs were considered. But I didn't have any. And mounting them would be not fun. Pneumatic or hydraulic struts... no, that's overkill from all points of view. I went to my towns hardware store. Not much there. And I saw a wire rope. A design idea came to me, bought 2 meters. Later used only one meter. At first it looked a hard work to attach the two plywood shelves together with this wire rope. This is how I did it.
I lined up two holed metal parts in same direction as bike moves normally, and spaced them 3.5cm from edges of shelves and 15cm from each other. I drilled 4mm holes in plywood all along them. You only need 2 holes at each end2,5cm apart. that makes 4 metal parts (instead you can use 8 pieces small, short ones with only 2 holes each. I bought such, but made my design with long ones anyway) times 2 ends times 2 holes each end and at the end makes 8 holes upper shelf and 8 holes lower shelf.
Now screw the bolts and metal parts together, just to hold it together. All 16 bolts have to go in. Hold one metal part rised and slide the wire rope under it, so it extends on the inside a few cm. Now screw the first two bolts firmly, so the wire is tight. This is the only reason, that will hold the upper shelf right on top of the lower shelf. That's why screws wont do it, you need bolts here. Make sure the wire is 90 degrees to the metal part.
Now comes a bit tricky holding it all where you want moment. Position the upper part over the lower and slide the wire rope same way, but other end from outside to inside over its metal part. This time slide almost all wire through and on the other side over the other metal thing (over metal, under upper shelf, between two bolts). Now connect the other side of both shelves with the rope going from out to inside under the third metal thing, just over the lower shelf, between two bolts. Now the construction gets a bit easier to hold. Be sure to twist the wire, so it rests as freely as possible. The only force acting upon it is the one because it is bent. Next wire it diagonally to the same, lower shelves other corner. Let it go through two bolts again, so it comes out on the right side. Now bend it and connect the upper shelve by wiring through its two screws from right side to inside. Continue the wiring straight out to the left side. The last place to connect, is the lower shelves left, closest to you corner. Do it! Connect it!
Now you have all the necessary wire rope where it should be, with only 2 bolts tight at one end. Adjust the length of the rope by pushing and pulling where necessary, to make both shelves aligned on top. Tighten the bolts in same order as the wire goes from the first two tight bolts. When all 16 bolts tight, you should have your construction as it will be. You shouldn't care about the metal parts bending. The only thing, that matters is that the wire is tightly screwed to the shelves.
I ended up with my shelves spaced apart some 6.5cm
I lined up two holed metal parts in same direction as bike moves normally, and spaced them 3.5cm from edges of shelves and 15cm from each other. I drilled 4mm holes in plywood all along them. You only need 2 holes at each end2,5cm apart. that makes 4 metal parts (instead you can use 8 pieces small, short ones with only 2 holes each. I bought such, but made my design with long ones anyway) times 2 ends times 2 holes each end and at the end makes 8 holes upper shelf and 8 holes lower shelf.
Now screw the bolts and metal parts together, just to hold it together. All 16 bolts have to go in. Hold one metal part rised and slide the wire rope under it, so it extends on the inside a few cm. Now screw the first two bolts firmly, so the wire is tight. This is the only reason, that will hold the upper shelf right on top of the lower shelf. That's why screws wont do it, you need bolts here. Make sure the wire is 90 degrees to the metal part.
Now comes a bit tricky holding it all where you want moment. Position the upper part over the lower and slide the wire rope same way, but other end from outside to inside over its metal part. This time slide almost all wire through and on the other side over the other metal thing (over metal, under upper shelf, between two bolts). Now connect the other side of both shelves with the rope going from out to inside under the third metal thing, just over the lower shelf, between two bolts. Now the construction gets a bit easier to hold. Be sure to twist the wire, so it rests as freely as possible. The only force acting upon it is the one because it is bent. Next wire it diagonally to the same, lower shelves other corner. Let it go through two bolts again, so it comes out on the right side. Now bend it and connect the upper shelve by wiring through its two screws from right side to inside. Continue the wiring straight out to the left side. The last place to connect, is the lower shelves left, closest to you corner. Do it! Connect it!
Now you have all the necessary wire rope where it should be, with only 2 bolts tight at one end. Adjust the length of the rope by pushing and pulling where necessary, to make both shelves aligned on top. Tighten the bolts in same order as the wire goes from the first two tight bolts. When all 16 bolts tight, you should have your construction as it will be. You shouldn't care about the metal parts bending. The only thing, that matters is that the wire is tightly screwed to the shelves.
I ended up with my shelves spaced apart some 6.5cm
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