Print PDF
Favorite
Email
Step 4Making the hitch assembly
Materials needed:''
2 x Remaining 2x4s from the deconstructed pallet
2 or 3 feet of 2x4 wood scraps
Procedure:''
(It may be easier to remove the wheels so that the trailer assembly will lie flat on the ground.)
1. You will need to cut 4 pieces of 2x4 to complete the hitch assembly. For the front crosspiece, measure the width of the trailer body without'' including the side rails and cut a piece to attach to the face. (It should be somewhere around 20".
2. Cut a piece for the upright that attaches at the base to the crosspiece. Use your bike to determine how high this should be. The hitch will attach to the metal post underneath the seat. The upright should measure around 19" or 20".
3. Cut the diagonal piece that will brace the hitch. It should be 24" long. Use a speed square, combo square, or protractor to draw a 45 degree line on each end and cut with the circular saw.
3. For the top connector you will need one of the 48" 2x4s from the deconstructed pallet. Depending on the size of your bike, you may want to shorten this piece to around 42" or 44". Use your bike as a reference to check this distance, bearing in mind that your rear wheel will need to be clear of the diagonal piece. (See finished trailer picture.) Save one of the triangle pieces that are left over from the 45 degree cuts.
4. Secure the front crosspiece to the face of the trailer using wood screws. (Pre-drill the holes for the screws.)
5. Position the upright piece roughly in the center of the crosspiece and screw it in at the base.
6. Ask a friend to hold the long connector piece on top of the upright. Secure with screws. Insert the triangle piece underneath the joint and secure with screws. Use the angle braces to secure the joint on the sides. (Your friend can let go now.)
7. (Optional) To make the hitch assembly more stable, you may with to secure it with 2 additional angle braces on the inside joint next to the triangle block.
8. From the 2x4 wood scrap, locate two pieces and cut them at 6" each. Using your bike, trace a circle in the middle that is slightly wider than the post under the seat. (There should be half of a circle on each block of wood so that they form a whole circle when placed together.) Cut out the half circles on each piece using a band saw or jig saw. (The turns may be too sharp for a band saw, try cutting the circle out in small sections if this is the case. It doesn't need to be perfectly round.)
9. Hold the two 6" blocks together lengthwise. Make marks for boring the bolt holes by checking the blocks against the end of the connector piece of the hitch. (The bolt locations should be easily wider than the connector that will attach in the middle.) Bore holes through both pieces of wood with a 5/16" or slightly larger drill bit. (This is a little tricky, You can bore through the first piece so that the tip of the bit marks a hole on the other side. Remove the top block and drill the rest of the way through the second block.) Repeat this process for the other side. The holes may need to be widened slightly so that the bolts will fit through both blocks. Secure the bolts temporarily with the 5/16" bolts with the washer and wing nut at the end.
10. Attach the 6" block assembly to the connector piece of the hitch by attaching a block across the top of both pieces. Screw the top block into both pieces. Make sure that this connection is very strong.
2 x Remaining 2x4s from the deconstructed pallet
2 or 3 feet of 2x4 wood scraps
Procedure:''
(It may be easier to remove the wheels so that the trailer assembly will lie flat on the ground.)
1. You will need to cut 4 pieces of 2x4 to complete the hitch assembly. For the front crosspiece, measure the width of the trailer body without'' including the side rails and cut a piece to attach to the face. (It should be somewhere around 20".
2. Cut a piece for the upright that attaches at the base to the crosspiece. Use your bike to determine how high this should be. The hitch will attach to the metal post underneath the seat. The upright should measure around 19" or 20".
3. Cut the diagonal piece that will brace the hitch. It should be 24" long. Use a speed square, combo square, or protractor to draw a 45 degree line on each end and cut with the circular saw.
3. For the top connector you will need one of the 48" 2x4s from the deconstructed pallet. Depending on the size of your bike, you may want to shorten this piece to around 42" or 44". Use your bike as a reference to check this distance, bearing in mind that your rear wheel will need to be clear of the diagonal piece. (See finished trailer picture.) Save one of the triangle pieces that are left over from the 45 degree cuts.
4. Secure the front crosspiece to the face of the trailer using wood screws. (Pre-drill the holes for the screws.)
5. Position the upright piece roughly in the center of the crosspiece and screw it in at the base.
6. Ask a friend to hold the long connector piece on top of the upright. Secure with screws. Insert the triangle piece underneath the joint and secure with screws. Use the angle braces to secure the joint on the sides. (Your friend can let go now.)
7. (Optional) To make the hitch assembly more stable, you may with to secure it with 2 additional angle braces on the inside joint next to the triangle block.
8. From the 2x4 wood scrap, locate two pieces and cut them at 6" each. Using your bike, trace a circle in the middle that is slightly wider than the post under the seat. (There should be half of a circle on each block of wood so that they form a whole circle when placed together.) Cut out the half circles on each piece using a band saw or jig saw. (The turns may be too sharp for a band saw, try cutting the circle out in small sections if this is the case. It doesn't need to be perfectly round.)
9. Hold the two 6" blocks together lengthwise. Make marks for boring the bolt holes by checking the blocks against the end of the connector piece of the hitch. (The bolt locations should be easily wider than the connector that will attach in the middle.) Bore holes through both pieces of wood with a 5/16" or slightly larger drill bit. (This is a little tricky, You can bore through the first piece so that the tip of the bit marks a hole on the other side. Remove the top block and drill the rest of the way through the second block.) Repeat this process for the other side. The holes may need to be widened slightly so that the bolts will fit through both blocks. Secure the bolts temporarily with the 5/16" bolts with the washer and wing nut at the end.
10. Attach the 6" block assembly to the connector piece of the hitch by attaching a block across the top of both pieces. Screw the top block into both pieces. Make sure that this connection is very strong.
| « Previous Step | Download PDFView All Steps | Next Step » |
 |
Add Comment
|
