Intro: CETMA Style Bolt Together Front Bike Rack
This instructable will show you how to build a bolt together front mounted bicycle rack. By way of reference, actual CETMA racks can be found for sale at cetmaracks.com
Step 1: Materials Needed
First get your materials. I used four pieces of 12 inch long, 1 inch steel tubing, 2 pieces of 1 inch angle iron at 18 inches long, 2 3/4 inch electrical conduit hangers (available at any hardware store in the electrical section), several 2 inch long bolts with nylon locknuts, 2 pieces of 1/2 inch steel stock at 20 inches long, 2 pieces of 1 inch steel stock at 24 inches long and a can of rustoleum.
For tools you will need an angle grinder or a hacksaw to cut the metal, a drill with metal bits, a measuring tape, safety glasses and some wrenches or a socket set.
Special thanks to my brother in law for donating the metal stock and tubing. These could be purchased or scrounged.
Step 2: Basic Frame
Bolt together the basic frame by drilling the guide holes and bolting it together.
Step 3: Bolt in the Rest of the Frame
Bolt in the rest of the frame. The middle frame struts should be spaced to match your hub width, the down struts will eventually bolt to them. Add any additional struts as you feel necessary. I was going to go with six, but went with 4.
Step 4: Cut and Bolt the Top Support
Measure the height you would like for the rack. It can go almost all the way down to the wheel. Cut your top support a couple inches higher than your handlebar and attach your conduit hangers where the rack will attach to the handlebars.
Step 5: Measure and Cut the Downstruts
Ok, so I forgot to take a picture of this step. Get an assistant and attach the top support to your handlebars. Push the frame out from the front of the bike till its level and have your assistant hold it level. Take one downstrut piece and line it up so it will attach to one of your middle crossbeams and will line up with your fork so the skewer will go through. Mark that spot and cut. Drill top support and skewer holes.
Step 6: Finalize
Fit, paint and attach to bike. Haul a ton of stuff!!