Instructables
Picture of How to Build a Longtail Cargo Bike
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We just made a longtail cargo bicycle from a second-hand Ukrainian mountain bike. It was made in Haiti with a minimum amount of tools and measuring, but it rides well. This bike has carried three adults (400 pounds total) without catastrophic failure. It is currently being tested/abused by the teenager pictured. Check out more of our projects at www.annbekan.blogspot.com
 
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Step 1: Find a bike

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Find a bicycle for as cheap as possible then cut the seat-stays about here, and the chain-stays just behind the bottom bracket.

Step 2: Find some metal

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Find some metal tubing. We found an old TV stand with strong tubing.

Step 3: Lay it out

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Lay it out and mark the tubing for more precise cutting. Aside from the TV stand tubing we also used a tube from a women's bicycle frame to strengthen the rear end.

Step 4: Build a jig

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I'm using the term "jig" very loosely. We found a piece of aluminium U-channel that was long enough and attached the frame to it in order to hold the frame in a straight line.

Step 5: Wire it up

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We used bailing wire to hold everything in place. Clamps would work better.

Step 6: Measure

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We used string and a ruler and a nail on the end of the string to build a plumb-bob. The goal is keep everything as straight as possible.

Step 7: Measure more

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Measure some more and cross your fingers.

Step 8: Find a welder

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We used this cheap stick welder and used 50-75 amps for all of the welding.

Step 9: Weld

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tack weld then measure/eyeball everything for alignment and weld some more.

Step 10: Weld

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Weld some more.  

Step 11: Paint it and name it

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We chose the name Cheval which means horse in Haitian Creole. Choose a font, make a stencil and paint it on.

Step 12: Admire it

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Our western style font is awesome. 

Step 13: Make a head-badge

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Every bicycle needs a head-badge.
Hey, thanks for the design!

I want to pick your brain a little bit--I pretty much need this bike, plus platforms and a heavy-duty kickstand so it won't be exactly the same...

First, do you have any concept of how much extra weight this put on the bike? i.e. are we talking five pounds or fifteen?

Second, have you tried making a sturdy kickstand for it? and if you have, what are the chances of you putting THOSE plans up too?

Thanks again :-)
depp.ben (author)  MountainMommaC2 years ago
Hi, I didn't add a kickstand. I don't have this bike anymore so I can't weigh the bike but I'm guessing this modification added 10 pounds to the bike. Goodluck.
harknirf4 years ago
 just built a bike like this based on this instructable, even used the same welding machine.  turned out great!  Thanks for the write-up/inspiration.
depp.ben (author)  harknirf4 years ago
That's awesome, I'm happy to hear it.
Don't let that 'chicken' into my coop! The cox comb doesn't fool me: the beak and head belong to a raptor. A great bike!
milly03454 years ago
cover those legs and arms not only against the sparks.I have the scars to prove that but the UV light  and use a mask
i was reading about a guy who was restoring his car and used a welder for prolonged periods (a few minutes at a time within like a few hours) he ended with a tan with tan lines the size of his goggles!
chadeau4 years ago
He said 'hole' ! lol
Koosie4 years ago
Awesome, that's like a pick-up-bike!
gmoon4 years ago
Great build--nice chickenhead welding mask, too.