Heavy Loads Bike Trailer




About: I live in the south Italy countryside, I have plenty of room to mess up with drill, grinder, saw and other stuff. I'm loving it.

This is my first trailer, I was inspired by several trailers found on Instructables, picking the best from all of them. I used a corner Aluminium profile, 40x40mm width (1,57 in) and 2mm thick (0,07 in) totally about 8 meters, a square aluminium pipe (40mm width), iron square pipe (30x30mm), tropicalized brackets, rivets, some bolts and nuts. Then I needed 2 16'' front bike wheels, beads (no matter the thickness), screws.
I had to buy more aluminium than needed but the total cost with right quantities is about 50-70 Euro.
as a test, 80 kg, about 175 pounds were smoothly transported. 

Step 1: What Is Needed

2 x 16'' bike front wheels
4 x 1mt aluminium corner profile - 2 of them with sides cuts at 45°
4 x 80cm aluminium corner profile - 2 of them with sides cuts at 45°
1 x aluminium square pipe (40mm wide)
10 x tropicalized brackets (4 flat 90°, 4 vertical 90°, 2 linear

4 x corner brackets
about 2m of iron square pipe 30mm wide (that replaced the round pipe in the image that was not working good)
beads (I used the 2cm thick ones)
rivets, screws, bolts and nuts
hand made gimbal

Step 2: Frame

After dlilling all the holes, rivet the corner brackets to the aluminium profile, using the 4 pieces cut @ 45°, until a square frame is obtained.
Rivet the 80mm aluminium profile (straight cut) at the center of the external long side to get a Z shaped side.
Add a 90° tropicalized bracket at the center of the bottom profile and grind it to fit in the profile. Cut with a grinder the center hole of the brackets to get a fork where you will fix the wheel hub.
Rivet the 1mt aluminium profile with the straight cut to the frame, at the bottom side, internally, leaving enough space to fit the wheel.
On these profiles, you have to rivet the other two 90° brackets making the same work of the previous.
Add longitudinally the square aluminium pipe at the center of the frame

Step 3: Wooden Parts

Shape the wooden base to fit the frame, then with 4 vertical square poles build the sides with the wooden beads and fit the whole structure into the aluminium frame. Fix the sides to the base.
Always with the beads, I shaped the wheel fenders, fixing them to the base and the sides with wood screws.

Step 4: Trailer Bar

Measure the height and the distance from the wheel of your bike, to get the trailer to stay horizontally, then cut the square iron pipe accordingly.
Insert the iron pipe into the aluminium pipe for about 50cm, then drill and add passing bolts. This will fix the trailer bar to the frame. If there's a little play between the two pipes, it's not a big problem, but if you want you can add some gauge between them and then add bolts, both on the vertical axis and on the horizontal axis.
Fix the corners with the remaining brackets (90° flat and linear) to give strenght to the whole bar

Step 5: Trailer Hitch

This is the trailer hitch that I did. It is very cheap (about 7 Euro) and you can see how to do it here.



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    12 Discussions


    2 years ago

    Curious if you have had issues with the trailer fishtailing with this setup hauling a heavier load?

    I have constructed an aluminum tow bar to modify my Burley to haul kayaks, but stability with a single gooseneck style towbar was a serious issue.


    4 years ago on Introduction

    Very nice work my friend! Out of curiosity, where did you happen to purchase the bike tires at? I can't seem to find any nearby.


    Reply 5 years ago on Introduction

    don't know exactly but it's about 25 kg, about 55 pounds, but with an average 18 speed mountain bike it is smooth. I am thinking to change the beads with thinner ones anyway, or find another solution for the sides, i'd like to get below 20 kg (45 lbs).


    5 years ago

    Very ingenious.


    5 years ago on Introduction

    Thank you all! It means very much to me. As an anticipation, i am working on adding seats for kids, paintwork and led light pack. It'll take a while. stay tuned!


    5 years ago on Introduction

    Very good design and painstakingly made, congratulation.


    5 years ago

    best trailer hitch I've seen for bike trailer! Have one of these stashed in the pile of 'shiny' at work. Will be coming home next week.