Introduction: Bicycle Rack for Heavy Load
When I was with my wife in north of Thailand, we decided to cycle more almost 1000 miles to islands in the south. We both have heavy backpacks and we needed good luggage carrier. Unfortunately all the ones we found were expensive and not suitable. So I collected materials around and with help of our friends we built these, that can carry more than 30Kg.
You will need (according to the size of your bicycle):
4m metal bar (sqare type 2x2cm or similar), that you will cut into smaller pieces (so if you have smaller pieces, you can use them) - you can also use any metal frame you might find at home like we did
2x metal angle (90°) 10cm wide
4x wooden plank 50cm long (whatever plank you find at home)
8x selfdrilling screws for metal (length 1cm+thicknes of the wood plank)
Welding machine (or friend who knows how to weld)
Battery powered screw driver(according to the screws you are going to use)
Drill with smallest drill bit you will have (Preparing the hole for screws)
Spray paint for metal (whatever color you like)
Step 1: Cut Your Frame
First of all you will need to know how big is your rack going to be. We had already the frame, so it was easier.
To have enough space for your luggage we do suggest the frame to be 30x50cm.
Then you need to cut:
2x 30cm of the metal bar
2x 50cm of the metal bar
Step 2: Weld the Frame
Either yourself, or your friend have to weld the 4 pieces together to make a rectangle frame.
Of course if you already had some kind of frame (as we did) you can skip these 2 steps.
Step 3: Measure and Cut the Attachment Bars
Place your frame on the top of your rear wheel so the end of the frame match with the end of your bicycle. It should be at least 5 cm above your wheel (to prevent anything getting stuck in the wheel).
Then measure the distance from your frame to the seat (where the screw for the seat adjustment is - 1. picture).
Take the measurments and cut 2 pieces of the metal rod accordingly (our was 20cm).
Measure the distance from corners of the frame to the center of the wheel (picture 2).
You will get two lenghts. According to each lenght cut 2 pieces of the metal rod (our was 45cm and 55cm).
Step 4: Weld the Attachment Bars
Take the attachment bars that goes from frame to the center of the wheel and weld them to the frame and to the 10cm angle on each side (1. and 2.picture).
First prepare it so that you can see at what angle the rods need to be attached.
Set your frame to the position and drill hole in the angle for the screw, that holds your wheel (if there are any screws around the wheel, you can use also these. Some bicycles have preparations for the rack).
Now you should be able to attach your frame to the bicycle. Either by using the additional screws, that are meant for holding racks, or by using the screw, that holds your wheel.
Once you have the frame attached with these screws make sure it is exactly horizontaly leveled (you can use spirit level).
When you have it leveled take the attachment rods that will go to your seat and place them each from one side of the seat rod and then straight to the frame. Measure the angle and mark the place, where they meet with your frame (3.picture)
Then take off the frame from your bicycle and weld these two rods accordingly.
Then place the whole frame back to your bicycle and drill holes for the screw under your seat.
Step 5: Paint Your Frame
Take of the whole frame and spray paint it the with the paint you choose.
It's better to use some good spray paint for metal, since it will protect it against rust.
Let the paint dry at least one day (it must be dry - it's not sticky when you touch it)
Step 6: Attach the Wood
Put the frame back on your bicycle. Take your 50cm wooden planks and distribute them evenly. Once they are in place take your drill with tiny bit and drill holes on each side of the plank through the wood and first part of the metal. When you drill all the holes take your screws and with screw them in to attach the wood with the frame.
You can use different materials like bamboo to have the frame lighter.
Step 7: Put Your Backpack on the Frame and Start Your Adventure!
Once you've finished your rack you can load it with your things and start your big adventure!
When you put the things in the back of your bicycle its good idea to attach some basket or holder to your handles and put some heavy things also there, so that you have the weight distributed a little (barrel of drinking water and tent is good idea)
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