Details of Fhule Bike Carrier

The photos on the previous page show the basic design of the carrier. Some of the dimensions are arbitrary and can be adjusted to fit different bikes. These measurements have worked well for a mix of adult and childrens mountain bikes.

  • Track is 53" in length, and constructed by slicing a piece of 2" PVC pipe in half lengthwise. A table saw or band saw will make quick work of this.
  • Base is made of wood ripped to 1 1/4" x 1 1/4" The height is not critical, but the width is the same as a Thule sports bar.....the U-bolts will fit best if you use these dimensions. Fir is ok, if you can find scrap pallet wood, all the better.
  • Stand is made from 3/4" OD electrical conduit. Each piece is about 26" long before you start bending. See the drawing for where to make the bends. I did it all using a bench vise.
  • Brackets are cut from 1 1/2" angle iron. I had this hanging around. You could also buy L brackets and save a lot of hack sawing.
  • Straps are 1" nylon with plastic buckles. I got this at the local sewing shop.

base.jpg

(Click to enlarge)

The two wooden pieces of the base are glued together. and reinforced with L brackets (angle iron) on the side. The wheel straps are sandwiched between the track and the base. I have the front strap almost at the cross piece, and the rear one 40" back.

 
I used the table saw to cut a groove down the length of the base, to contour it to the track. The track is fastened to the base in the front with a 1/4 x 2" carriage bolt. The rest of the track can be fastened using pan head screws and construction adhesive. The bolt holes are recessed on the underside, and bolts are cut off flush.
The stands are what truly holds the bike on. These are attached to brackets bolted to the base. There is about an 11" spread between the legs. The brackets are simply a piece of 1 1/2" angle iron cut 1 1/4" wide and a couple of holes drilled: one to hold it to the base, the other to attach the stand. For the stand, use a lock nut and washers.

(Click to enlarge)

(Click to enlarge)

 Here is a bit more detail of how the stand clamps to the bike. Get a piece of 3/4" ID plastic hose to slip over the conduit. Drill the hole for the tightener bolt a little oversize so the legs will spread easier.
When you assemble the stand, be sure to orient the tightnening bolt so it works from the same side as the wheel strap buckles. And if you are making more than one carrier, make them mirror images....so they operate from opposite sides of the car.
Once assembled, the carrier is attached to your roof rack or sports bar using squared off U-bolts. The two in the front just slide over the stand brackets. For the rear, you will have to mark off where the base crosses the rear sports bar, and drill holes through the track.

(Click to enlarge)

Well that's about it....I hope you get as much use from these as I have, along with the satisfaction of keeping $300 out of the economy and in your pocket.

Back