Heavy Duty Bike Trailer

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Introduction: Heavy Duty Bike Trailer

I am making a heavy duty bike trailer for hauling pallet boardwalk sections for my other project featured in Instructables, The Upcycled Nature Boardwalk. I wanted to make something that was durable for 200 lbs and able to go through the mud.

Supplies

Supplies:

chop saw

hand tools for mearsuring

drill pipe clamps

3/4 metal conduit wheelbarrow wheels

5 inch 1/2 bolt machine thread conduit bender

2 inch ball and hitch

Step 1: Building the Frame

Very simple, just 2x4s six feet long and 30 inches wide. It is very helpful to have a table with raised edges that are square. I prefer to use 2 1/2 inch long deck screw to hold it all together.

Step 2: Building the Wheels and Axle

I picked up some wheelbarrow wheels for this project given the weight I am insterested in hauling plus the muddy trails I will be on. I created an axle inspired by this You Tube video. I used 3/4 inch EMT electrical conduit with a five inch machine bolt through the wheel. I drilled a hole through the bolt and held the whole thing together with a cotter pin.

Step 3: Atttaching the Axle

i used pipe clamps and some rings that came with the wheel to make a snug grab of the axle to the underside of the frame. I put it to the back at first but later moved it to the center.

Step 4: Buiding the Hitch

I used more 3/4 inch EMT conduit to fashion the tow hitch. I also had to get a special tool for bending it to the shape I needed, and of course there are hundreds of how to videos for this trick. I watched this one. Not that tough really, and you feel like Robo Man bending metal, so it's fun.

Step 5: Building the Armature for the Hitch

I used a standard 2inch wide hitch that is coulpled with a two inch ball. I was inspired by Fatcamper's Instructable on this approach after looking at lots of DIY hitches. I want something that can handle the weight and not be too cumbersome to attach. I used 2x2 square PT lumber and a mahogany spacer to make my attachment. I used U rings to make the connection built abandoned it later for 1/2 screws. (NOT shown) . My bike is a cargo bike with a very long rack that allows for a pretty beefy ball as you see.

Step 6: Trying It Out

After the first test drive, it seemed like the EMT tubing could use a little stiffening so I added a cross brace, and ground down one edge of it to make a good connection with the round pipe

Step 7: Stronger Axle

The Metal conduit works great for the curved hitch, not so great for the axle which bent under heavy loads. So I installed 10 inch long 1/2 inch diameter bolts inside the the conduit and added more supports right up to the inside face of the wheel. Much stronger. I also bolted on the box from the old trailer temporarily for plant pick up from the local farm.

Step 8: Many Uses for My Trailer

I took my other bike down to the river, then took the kayak to a different part of the river and did some paddling.

I will stack the trailer again with pallets when I build them.

I also saw a commercially made trailer and decided to add removable brackets, which you can see in detail.

2x4s (about 10 eight footers) and two inch long screws were all I needed for the removable fencing. Very handy for trashcans, or perhaps something odder, like a bed? Stay tuned fans.

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    10 Comments

    0
    making is great
    making is great

    Question 1 year ago

    What size wheel did you use? Great project!

    0
    Dandda14
    Dandda14

    Answer 1 year ago

    I used a 14.5 inch Marathon Universal Fit Wheelbarrow Replacement from Home Depot...thanks

    0
    making is great
    making is great

    Reply 1 year ago

    Do you think that a 10" wheel would work?

    0
    Dandda14
    Dandda14

    Reply 1 year ago

    Should be fine....I went with wheelbarrow wheels because I wanted to carry a lot of weight

    0
    Ashmadeva
    Ashmadeva

    1 year ago

    Now that is a great project. I take it you have legs of Superman, surely hauling a load has got to be a serious workout.

    0
    Dandda14
    Dandda14

    Reply 1 year ago

    I certainly would have a hard time hauling on a trail without the electric assist

    0
    Ashmadeva
    Ashmadeva

    Reply 1 year ago

    Actually read the article on the nature walk and learned you're using an electric bike.ni have so many question about electric bike motors and hauling capacity... For another day

    0
    Dandda14
    Dandda14

    Reply 1 year ago

    sure I am happy to address your questions...Dan

    0
    tmspro
    tmspro

    Question 1 year ago

    Great build!. About how much does the trailer weigh?

    0
    Dandda14
    Dandda14

    Reply 1 year ago

    currently about 40 lbs...I can lift it to do work, but I plan to add decking soon so that will change..The wheels are the heaviest part, but as I have an electric assist bicycle I can make it heavy...