Street Sign Bicycle Basket

Materials

- 1/8" grip rivets (80 @ 3/16" diameter)

- riveter

- 11" x 13" aluminum street sign pieces (2@ 1/16" thick for front and back)

- 13" x 13" aluminum street sign piece (1@ 16" thick for base)

- 11" x 13 1/8" aluminum street sign pieces (2@ 1/16" thick for right and left sides)

- clamps

- cordless drill with 3/16" bits

- 1 1/4" diameter hole saw bit

- rubber blow hammer and punches (for rivet hole placement)

- metal file to smooth sharp edges

- ruler/ tape measure

- shear for cutting signs

- 3/64" x 3/4" equal leg aluminum angles (8 pieces @10 7/8" each)

- hacksaw for cutting leg angles

Step 1: Cut Base and Side Pieces

Begin by using a shear (or aluminum-compatible saw) to cut your pieces.
Trace your pieces using a pencil or marker so that you have straight lines (to use as cutting guides -- a T-square is a good idea).

- 11" x 13" aluminum street sign pieces (2@ 1/16" thick for front and back)

- 13" x 13" aluminum street sign piece (1@ 16" thick for base)

11" x 13 1/8" aluminum street sign pieces (2@ 1/16" thick for right and left sides)

Step 2: Cut Leg Angle Pieces

Cut your leg angle pieces using a hacksaw.

You will need 8 pieces that are 10 7/8 long. Clamp the pieces securely to the table with the amount to be cut overlapping the side of the table. Label each piece so that each leg and base angle corresponds with a facet of both the base and vertical angles.

Step 3: Drill Holes in Base (for Zip-ties)

Drill holes in base, working with smaller drill bits until you can reach a larger diameter. See diagram for spacing.

Step 4: Drill Holes in Side Pieces

Drill holes in sides, 1 1/4” diameter. The center of the circle is spaced 1” from the top edge and is centered on each panel. Use your hole saw drill bit for this step.

Step 5: Getting Ready to Drill Holes

Align the spines of the angles with the edges of the base.
Clamp the angle to the base on both sides.

Center the piece along the edge so that you have space in the corners.

Plot a line of holes down the center of both sides of the angle with 2 1/2” spacing between each, offset 1/4” from each end.

Step 6: Drill Your Rivet Holes

Drill each panel while clamped to its corresponding leg angle to ensure that the holes will line up. Clamp everything together to maintain accuracy!

Drill your holes using a smaller bit first, then switch to a 3/16” size to match the rivet diameter.

Step 7: Beginning Your Rivets

Rivet the leg angles to the base first.

Step 8: Continue Riveting Process for Sides

Repeat this step for all other sides, including vertical pieces.

The vertical pieces will be placed along the side panels so that their top edges align with the top edges of the side panels.

Step 9: Final Assembly

Rivet all side panels together in a hollow square.

Place this hollow square. Over the base so that all pre-drilled holes line up. Rivet this outer frame to the base.

You are finished!

Step 10: Completed Version

Your box is ready to be attached to the back of your bike!