These instructions are broken down as follows:
1. Parts Needed
2. How to build the rack
3. Other tips and tricks
Step 1: Materials Needed
The first list is a list of all the parts you must purchase or already possess to complete this bike rack.
The second document is a list of how many pieces of each size PVC pipe must be cut. Please check with your hardware store when you arrive as many will cut the two long pieces of PVC pipe for you into all the correct sizes. This may require payment but could still be the best way to go if you want the cuts to be perfect.
Unfortunately Instructables will not currently allow the PDF files to be uploaded. Please copy and paste the links below into your web browser.
Parts to Purchase - http://dl.dropbox.com/u/62619448/Parts%20to%20Purchase.pdf
Parts to Cut - http://dl.dropbox.com/u/62619448/Parts%20to%20Cut.pdf
Step 2: Cut the PVC Pipes
If you will have this done, please use the Parts to Cut list to provide the employee with the sizes and quantities of each part needed. You will have a 5'8" piece of PVC pipe remaining after all cuts are made, so it can be saved for later use.
If you decide to cut the pipes yourself we recommend using a vice or other tool to hold the pipe securely in place while cutting. This will ensure the most even cuts are made.
For those who will have PVC pipe cut at the store, skip ahead to Step 5, where construction of the rack begins.
Step 3: How to Cut First Long PVC Pipe
Take one of the long pipes and divide it into parts A and B - two 3 foot sections and two 2 foot sections. You can do this with a measuring tape and a marker.
Cut the first pipe into the four pieces measured, parts A and B.
Step 4: How to Cut Second Long PVC Pipe
Mark it into three 9" sections, one 6" section, two 3" sections, and six 2" sections. Once measured and marked, cut the pipe into all of these sections, which will complete parts C, D, E, and F.
Now you have all the necessary cuts complete and the two parts lists will be used from now on to refer to each piece.
Step 5: Assemble the Two Legs
These end caps need not be glued to the pipes unless they do not fit firmly on.
Step 6: Assemble the Bottom Crossbar
Step 7: Assemble the Middle Bars
Step 8: Assemble the Bike Holders
Insert and glue a Part F into each Part 4.
Then, attach an end cap, Part 6, to the other end of each Part 4.
Finally, glue each exposed Part F into the Parts 5 on the two middle bars created in the last step, with all four in the same direction.
Step 9: Assemble the Top Crossbar
Step 10: Attach Top and Bottom Crossbars to Middle Bars
Now, attach the Bottom Crossbar to the Middle Bars by inserting the 9" Pipes (Part C) into the bottom of the Middle Bar Assembly.
Once you are sure that your rack appears as the image above glue all of these connections together.
Step 11: Attach the Legs and Adjust Orientation
Attach both legs to the Bottom Crossbar using one Part 2 and one Part F for each leg. The 45 degree PVC connector should be glued to the open end of each leg, and a 2" PVC Connector Pipe (Part F) should be used to connect each Part 2 to each Part 7 on the Bottom Crossbar. See the picture above for an image of this. Glue each Part F into each Part 7 of the Bottom Crossbar, but do not yet glue the Part F into the Part 2.
Now, apply some glue to one Part 2, place it on the Part F protruding from the Bottom Crossbar, and rotate it so the leg is about 30 degrees outward. Hold it in place or use something to hold it until the glue hardens it into place. Repeat this step for the other leg.
Step 12: More Tips and Information
First, we recommend that you always use the bottom bike holder if only using one bike. Going along with this, always place a bike on the bottom holder before placing one on the top, as this will keep the rack much more stable.
If you have trouble keeping it standing against a wall, small rubber pads can purchased and attached to the ends of both legs. This should keep the rack from sliding on smooth floors such as cement, tile, or hardwood.
Also, a hole can be drilled through the top crossbar and you can add a wire to it that can better secure it against the wall.
We will continue to work on this bike rack and make improvements to it, so please check back later if you have trouble with building yours.
Thank you for looking!