Conduit Bike Trailer

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Intro: Conduit Bike Trailer

Build a nice bike trailer out of a piece of electrical conduit and some old bike bits

Step 1: What You Need

Two bike forks
wheels for the forks
A piece of 10' steel electrical conduit that can fit (snuggly-ish)over the head of the bike fork. 1" conduit worked for me
A piece of thinner conduit, also steel. This is to make a brace or two
A sturdy piece of wood. I initially used a broomstick, which prompty shattered. A 2x3 worked (and is still working...)
Two old bike inner tubes. Get these from the dumpster behind a bike store, or your enemies' bikes




the plumbing pipes in the picture have nothing to do with the project--they're just living their lives, not bothering anybody, so I say, live and let live, right?

Step 2: Ways to Build It

I can think of three ways to assemble this, all of which would work pretty well.
The differences are how you attach the bits of conduit to one another.

You could:
Weld
Bolt
Lash with inner tubes

I used a MIG welder, because I wanted welding practice. If you wanted to bolt instead, every time I weld two pieces together, you would drill a hole through them and stick a bolt through it. You'll probably want to whack the conduit a bit where you'll be drilling to flatten it out.
If you're lashing, then just lash, man.


THIS IS REALLY IMPORTANT!
If you're welding, be sure that you don't have galvanized conduit. Seriously--welding galvanized steel frees criminal molecules that had been locked up in their metallic prison, and the criminal molecules run through the air into your lungs and try to kill you. So seriously, don't weld galvanized stuff.

also, if you're welding, make sure all your conduit is steel. Otherwise it probably won't work.

Step 3: Bend the Conduit.

Take the 1" conduit, and bend it to make a
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kind of shape. There are several instructables on how to bend tubing. I tried to cheat and shape my tubing around a restaurant's oil drum, and ended up crimping it by mistake, but the conduit's still strong in the direction that it will get stressed.



Here's Ricketts, modeling with the bent conduit. It's really an ugly bend. I'm sorry :(

Step 4: Attach the Forks

Take your bike forks (keep the wheels off them for now) and stick them into the open ends of the conduit. Use your preferred method of attaching them. Take a second to make sure they're aligned with eachother, and that they're perpendicular to the ground.

Step 5: BRACE!

Use a hacksaw, pipe cutter, or grinder to cut a piece off the other conduit that will brace across your frame. Attach it near the wheels.
The picture's pretty self-explanatory, I think

Step 6: Lengthwise Thingy

Now, cut another piece of conduit that can run length-wise. This isn't very structural, but it's handy to attach things to them when you want to trail around.
Attach it down the center of the frame.

I made mine really long originally, thinking that I could use it as the tongue that attaches to the bike. Then I remembered that conduit can bend pretty easily and cut it off at the top of the frame

Step 7: Put the Wheels On

put the wheels on
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put the wheels on
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put the wheels on

Step 8: La Lingua

The tongue is the piece of wood that will attach to your bike. You probably want 3 feet or so between the bike and the trailer, and then overlap a couple of feet (or more!) with the conduit running down the center of the frame.
Use a piece of inner tube to lash the tongue to the conduit.



Step 9: Attach It to Da Bike

Now, attach the tongue to your bike seat with another inner tube. Lash it tightly.

Step 10: Done!

sweet, you're done
Go bike around and haul things.
I'm pretty sure I wouldn't trust it with a human's weight, but I used this trailer to carry my laundry to and from the laundromat, and also to shlepp 2 4x8 sheets of plywood a couple of miles, and it's worked really well so far.

Enjoy!

alex hornstein
http://www.artiswrong.com

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    34 Discussions

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    Brother_Bear

    12 years ago

    Breathing in the fumes from welding galvanized steel and iron doesn´t kill you it only makes you sick enough to wish it did. Here in sweden its called "Galv-frossa" which means literly the "galvanized-shakes" but a better expression would probably be "the Zink-shakes" beacuse its the fumes from the heated Zink-layer that is the culprit. Its quite common among foundry/steel-workers who work with galvanised steel here in sweden and they supossedly build up an immunity to the shakes over time.

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    jsadler1Brother_Bear

    Reply 2 years ago

    In the US, it is usually called zinc shakes. It may be mild and a few minutes walking it off might do. But it can be quite serious and I am in favor of calling an ambulance just in case. I really doubt that anyone become immune to it. I suspect that most people who weld get smarter and use better ventilation after they get a mild dose of zinc shakes.

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    prankBrother_Bear

    Reply 12 years ago

    Yeah, but if you're in an area with crappy ventilation, I heard it can wreak havoc with your system. An interesting thing a friend was telling me--In the US, Galv-frossa is called Monday Night Fever. Professional welders can get a tolerance for zinc fumes over time, so during the week, when they are constantly exposed to fumes, they are pretty immune to it, but over the weekend, their tolerance drops back down, so they all get sick monday night. The first time I welded, I got horrible flu-like symptoms within about an hour. I was welding bike tubing, so I still don't know what caused it, since I don't think that it's galvanized. Maybe I missed some paint when I was grinding a clear spot to weld, and breathed paint vapors. Anyway, it sucked.

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    sleeping_gecko

    12 years ago on Step 9

    I've not done much with innertube lashing, so I don't know how much friction it would provide for the hole here. I was thinking you might want to drill a hole 6" or so from the end of the wood (6" from the front), and put a nail (with the point filed/ground off) through it. You could bend a rounded 90 degree angle into it, so it could hook around your seatpost a bit. This might be a good idea (especially with heavier loads).

    3 replies
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    jsadler1sleeping_gecko

    Reply 2 years ago

    I have lashed with inner tubes and they can be quite strong. Usually, you'll need more inner tubes than you would expect to use.

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    pranksleeping_gecko

    Reply 11 years ago on Step 9

    I've pulled ~300 pound loads with innertube lashings without a problem. Innertubes have so much friction that they can hold pieces together incredibly well. Just be sure to lash them tightly

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    sleeping_geckoprank

    Reply 11 years ago on Step 9

    That's quite a substantial load. I was seriously considering building one of these, but I'm in a dorm building on a college campus, and my spare bike parts are at home, so I don't have them with me and I have no place to store it.

    And then, a few months ago, my bike got stolen. It was right after I put on the chrome fenders that I had brought back from the junk bike I bought in Japan when I was there, too. But other than that, it didn't have much worth left to it other than being an abusable college-student bike (front derailer=gone, rear derailer=3 or 4 gears, instead of 5, depending on its mood, rear brake=gone, a spoke or two on the rear wheel=gone, tires and most of the non-painted parts=crapped up and nasty from the better part of a year and a half of sitting outside through rain, snow, freezing cold, boiling heat).

    I miss it though. I do a lot of walking now. I loved riding in snow last winter.

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    ckassor

    11 years ago on Introduction

    if you don't want to weld the forks into the frame, how else could you do it securely? i'm thinking of making a trailer similar to this, but out of pvc pipe. i don't know how to keep the forks secure, though.

    4 replies
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    prankckassor

    Reply 11 years ago on Introduction

    I'd drill a hole through the fork and the pvc pipe, line up the holes and throw a bolt through them with some nice wide washers and a lockwasher to keep the nut from coming loose

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    jsadler1prank

    Reply 2 years ago

    You might want to try a nylon type of nut with the steel threads. I believe they are called nylock nuts.

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    remal boon

    8 years ago on Step 3

    Industrial tube benders have springs that go inside the tube to stop it crimping. I think you can also protect it by filling the tube with sand before you bend it. The principle is just to get something flexible enough to bend inside the tube but which will resist the tube being compressed.

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    jsadler1remal boon

    Reply 2 years ago

    Spring benders are used on the outside of small tubing to control the bend. The spring is the bender. For high-quality work, a mixture of water and a bit of dish soap is frozen inside a tube before it is bent. That keeps it round. Sand can be used but must be tamped down in the tube in such a way that it has no place to move about So it is best to seal the ends, then bend, then remove the sand. But the old time way may be the best way. Use caution and fill the tube with molten lead. When it cools make the bend. Then heat the tube to capture the melting lead into a container. Molten lead is best handled by adults who have some experience as you can be seriously injured or killed.

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    Gary James

    8 years ago on Introduction

    if you don't want to weld the forks into the frame, how else could you do it securely? i'm thinking of making a trailer similar to this, but out of pvc pipe. i don't know how to keep the forks secure, though.

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    2 stroke Gary James

    Reply 8 years ago on Introduction

    drill a hot through the fork stem and pvc strait and put a bolt and a llock nut to hold it i dont know a bout pvc i know it is weak and flexable you probable will want to sue wood or steel pip and rent or buy a cheap welder the wlder will e useful for other stuff too

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    mattbomb

    8 years ago on Step 9

    dude now this is making use of what ya got. this is great man. awesome trailer design

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    curley1

    9 years ago on Step 10

    Lol! That's the first one I've seen hauling a full sheet of plywood. I like the simplicity of this low cost design. Have you tried to make a single wheel trailer out of conduit?

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    curley1

    9 years ago on Step 8

    You could use 1" conduit clamps to attach it. Either through-bolted or with big wood screws.

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    sayoian99

    9 years ago on Step 7

    good tip...jk! but seriously,not half bad.