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as promised in my last instructable, here's my attempt to build a 2-wheeler. why? i got infected by the bike-building virus. especially cargo bikes are just awesome vehicles: you meet lots of new people ("hey, what's this?"), you can transport nearly everything you need on a regular basis and it's better than a car if you live in a city like me (no parking fees, no searching for space to park a car, no insurances, taxes, gasoline, healthier & better for the environment,...). so go on and build your own, it's not that hard ;-)
 
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Step 1: Donor frames

(sorry no pic) i got myself two donor frames from the local dump: an old 26'' mountainbike (hardtail) and a 20'' kids bike. the kids bike is just needed for the front fork and wheel, so if you find one where everything else is rusty and broken - take it! the other bike is used as a whole.
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Neander says: Mar 15, 2013. 11:02 PM
That is cool! I plan on making one like this but from a 3-wheel bike, so I have front and rear cargo space!
carkat (author) in reply to NeanderMar 19, 2013. 11:56 AM
sounds great! if you're done with it a pic of your work would be highly appreciated. thanks!
Neander in reply to carkatMar 19, 2013. 8:59 PM
Definately!
bpurcell2 says: Nov 1, 2011. 6:20 PM
Brakes--The weakest point of the two bakfiets I've built are the brakes. I'm one use a cantilever on the rear and a BMX side-pull for the front. The other uses old MAFAC racers front and rear--I've found that with a full load and going down a hill brakes are weak. On the next build I hope to use discs, especially on the the front.

Rap
carkat (author) in reply to bpurcell2Nov 2, 2011. 12:31 PM
yes, i can confirm that. though my cantilevers at the back are good enough, but the ones in the front are definitely too weak. the best solution would be disk brakes i guess.
nthomas12 in reply to carkatNov 19, 2012. 5:35 PM
Hey, so I'm pretty far along with my bike, coming along pretty well, and I'm going to attempt to go with disc brakes!! My biggest question for anyone out there is: how did you all engineer the kickstand to stay up when not in use? I'm assuming that professionally built bikes have some kind of spring mechanism, but not sure how I could build this?
carkat (author) in reply to nthomas12Nov 19, 2012. 11:57 PM

nthomas12 in reply to carkatNov 20, 2012. 7:22 AM
Thank you very much, that's exactly what I was needing!!
theboatdriver says: Nov 14, 2011. 12:33 PM
really nice!! im planning on building one next month, already gathered everything except for the steel.
I was wondering how you've put the outer cups from the headset in the long headtube? (or did you find a tube with the exact diameter?)
I was thinking to get a tube with a bigger diameter than the original headtube, cutting the headtube in half and weld it to the tube with the bigger diameter...
or is there an easier solution??

:-)
nthomas12 in reply to theboatdriverOct 6, 2012. 3:49 PM
I had the same question, but my headtube wasn't long enough to cut in half, so I luckily had a 3rd frame, cut it's headtube off and will weld it to the bottom of the steerer tube.

BTW don't know if anyone has advice, but I'm brazing everything because I don't have a working TIG welder at my disposal. Seems to work ok, what do you think?
carkat (author) in reply to nthomas12Oct 7, 2012. 12:35 AM
i don't use a tig either. there should be no problems with brazing.
carkat (author) in reply to theboatdriverNov 14, 2011. 2:49 PM
yep, i had a tube with the exact diameter for the headset (34 mm. steel was 36x2 mm), but i think your idea will definitely work. though i guess if you spend some time to find the right diameter for a bigger tube to enclose the headtube you maybe could find a tube with the measurements of the headtube, too.
good luck with your project!
bainslie says: Sep 26, 2011. 7:00 AM
Fantastic build dude. I knocked one up myself recently with the help of a marine engineer mate who himself had made one first. Here's some stuff we learned.

Rod end bearings for both ends of the steering rod offer superior resistance in hard knocks [running into curbs/walls under load, etc]

a variation on the bucket style cargo area is the "deck" or "tray" style area with sides that fold down to make a totally flat tray for awkward loads [like old bike frames that have been chucked out ^_^] which can be more versatile. We were initially worried that without sides loads would slide out in corners, but the strange property [and vastly superior nature] of two wheeled cargo bikes is that they'll lean in the corners and most loads, if not really light, will stay right where they are. Of course if you have young children then that all goes out the window.

We also found that using a ladies mountain bike frame meant that in the [no doubt extremely unlikely] event of falling over sideways, the top tube of the frame doesn't tend to take you with it.

On the notion of moving the steering mount point higher on the front fork, it *does* allows your hard lock left to be a lot further left but we needed to do SO much readjusting and fine tuning to make sure that it would clear all the various bits that are so close together in there [we ended up cutting a groove roughly the circumference of a tennis ball into the front of the cargo deck] having said that, I've never ridden a bike without the clearance, and I would imagine it's pretty constricting.

Anyway, as I said, awesome build, it looks really schmick and it's always great to see another nutter on the cargo bike convoy.

Well done.
nthomas12 in reply to bainslieOct 6, 2012. 9:01 AM
I'd love a pic of what you did for the steering problems you mentioned!! I just started building one of my own!!!
bainslie in reply to nthomas12Oct 6, 2012. 4:31 PM
Sure thing! It's actually just a frame at the moment as I'm going to get it powder coated to try and give it a good shot at rust protection, so when its all back together I'll snap a few.
carkat (author) in reply to nthomas12Oct 6, 2012. 12:47 PM
a maybe better solution would be a cable/chain steering as done here: http://flic.kr/p/a6ackh
btw.: have a look at the other pics there. this guy is a genius. i only discovered his work recently.
nunja business in reply to carkatNov 11, 2012. 11:34 AM
Thank you for helping me kill a good bit of a morning when I went to his flickr site. You are right - some very clever solutions he has come up with and some interesting designs. I found most enlightening that he uses "girl's bike" frames when possible because of the lack of obstruction bar for getting on and off.
carkat (author) in reply to bainslieSep 26, 2011. 12:25 PM
hey, thanks a lot for sharing your experiences!
guruji1 says: Jun 29, 2012. 4:19 AM
Very good idea. Regards for this project. I think would be better if one can attach same type of carrier to a normal bike. So that it can be removed when not in need. The worst part to make the two front wheels syncronisation.
Anyway thanks to share.
nthomas12 in reply to guruji1Oct 6, 2012. 6:57 AM
I've seen this, it's very High Tech because of how the cargo box attaches to the bikes fork. I think it was a 3 wheeled version. I think they cost upwards of $5000.00 and probably would be difficult to engineer to build yourself. :)
carkat (author) in reply to nthomas12Oct 6, 2012. 12:38 PM
wow, that sounds interesting. any chance you could dig out a link to that? or some other hint? thanks!
carkat (author) in reply to guruji1Jul 1, 2012. 11:49 PM
thanks! sync'ing the front wheels should be quite easy (it just would need two steering-rods) but mounting the front part in a way that it works even for heavier loads will be hard to do, i guess. though... why not try? would be a good idea for a nice project :-)
nthomas12 in reply to carkatOct 7, 2012. 7:49 AM
http://www.myzigo.com
So this is the bike I saw that converts from Bike to Cargo bike, to stroller. It's not really much of a cargo bike, just a child carrier. Of course sometimes when you have something so convertible, none of the individual functions work as well. I have no idea with this product. It does look like you can't cary very much weight with it.
carkat (author) in reply to nthomas12Oct 7, 2012. 11:34 AM
thanks for the link!
nthomas12 says: Oct 6, 2012. 7:02 AM
Thanks for this project, I've started work on it myself. A couple logistical questions though... For the headtube extension, did you have tubing that had the correct ID for the lower bearing race to fit? I'm taking a 3rd donor bike's headtube and welding it to the bottom because my extension tube has the wrong inner diameter.

2nd, how long is your box? I'm just trying to get a good sense, I can figure out a good length, just wondering what you used so I have something to go on? Thanks again, I'm really excited to get this thing going.
carkat (author) in reply to nthomas12Oct 6, 2012. 12:36 PM
yes, i had a tubing with the correct inner diameter for the headtube extension. luckily.

box length at the bottom is 80 cm. though in the meantime i've come to the conclusion i should have meade it shorter. all in all the bike has a very long wheelbase which makes turning not easy sometimes. i would recommend to build it just as long as you really need it. if in doubt build a cardboard model in scale 1:1. holding it to the bike gives you a good guess.
bpurcell2 says: Nov 1, 2011. 6:21 PM
Nice Build BTW--you've given me some ideas.

Rap
carkat (author) in reply to bpurcell2Nov 2, 2011. 12:26 PM
thanks!
gsport george says: Sep 27, 2011. 4:46 PM
Nice.
Where do you store it?
This is mine:-
http://www.instructables.com/id/Long-John-Cargo-Bike/
and I have had to build a small lean to to keep it in...
Interesting that we both went with Orange...
carkat (author) in reply to gsport georgeSep 28, 2011. 12:55 AM
thanks. of course i know your instructable ;-) was a great inspiration, though well above my capabilities (welding aluminium!). both of my cargobikes and my road bike are stored in the inner courtyard of the house we live in. in winter it gets a simple plastic foil as garage.
greybear2k5 says: Sep 22, 2011. 4:38 PM
Saw a lot like this in Amsterdam, not sure if they were homebrew or if someone actually sells cargo bikes there.
carkat (author) in reply to greybear2k5Sep 23, 2011. 12:54 AM
colinus says: Sep 22, 2011. 2:01 AM
Wow, nice!
Figure I've made exactly the same thing two years ago. But someone has stolen the bike! Too sad.
Did you experience stiffness problems? Mine was like a chewing-gum frame, and really heavy (25 kilograms).
I'd be happy to see a video of the bike in use!
Great work.
carkat (author) in reply to colinusSep 22, 2011. 2:39 AM
stiffness is fine. the only thing one has get used to is the long wheelbase (more than two meters). and, yes, it is heavy. but it's a lorry not a porsche, so i'm fine with it. i'm just a bit slow when it gets hilly but that's ok. a video will be made next time i don't forget the camera, promised!
carlitos says: Sep 21, 2011. 1:53 PM
Nice idea. You can add seatbelts for transporting humans.
The mechanism for steering the front wheel reminds me
of Olli Erkkila's forkless cruiser bike.
http://www.ollierkkila.com/Site/?page_id=4&album=11&gallery=70
http://www.youtube.com/watch?v=7qiR7E3dpjk
carkat (author) in reply to carlitosSep 22, 2011. 1:18 AM
thanks! the cruiser bike looks quite funny. i wonder how it rides - if it's bouncy or hard to steer...
carkat (author) in reply to carkatSep 22, 2011. 2:18 AM
by the way: seatbelts were already mounted, but my kids didn't like to ride in it. they said it's going too fast... probably they're just used to sit in my other cargo bike which is a bit heavier to pedal and is not tilting in curves.
zazenergy says: Sep 21, 2011. 12:06 PM
Wow, such a great job!
carkat (author) in reply to zazenergySep 22, 2011. 1:18 AM
thanks a lot!
RayKenn says: Sep 21, 2011. 4:47 AM
Excellent project ! Thanks for sharing the details.
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