Homebuilt porteur rack v1.0

I have long found that the humble rucksack is just not adaptable enough (and leaves you with a sweaty back) and deciding something like a porteur rack would suit my mash perfectly, I was rather disgusted by the ridiculous pricing for the only two which seemed to fit my need: the Soma Porteur at £100, or the Velo Orange Porteur (huh, they named their racks the same, that was silly, they'll get confused) also at £100 (neither with rail), which are both awesome and very well made, but too expensive for me by far.

This obviously needed to be rectified, but as I don't currently have mad welding skillz, I'd have to go about it from a slightly different approach.

So, tonight I have ordered some alu 3mm cross hatched plate, 1/2" tubing, 30mm x 3mm flat bar, and 1/2" square section.

I will try and post pics as I go, and as long as I choose my materials well, this really shouldn't be difficult for anyone with a bit of mechanical aptitude (a very small amount really) and some patience to achieve themselves.

If it works really well and there is interest in a sensibly priced custom rack for people without the aptitude, or indeed patience, I might decide to make a few more, but bear in mind, there will be a 5% forum contributions tax.

I'll also be interested in what people have to think, so please leave constructive comments and ideas.

Photos to follow, when I actually have something to show you!

diy threads are always a potential win.

Can you weld, AngelID?

Like the sound of this.

Can you weld, AngelID?

Nope, but wish I could.

By the way, after deciding to build me own and searching around for photo search for "porteur rack" on google heres the original thread I found here right here on LFGSS - https://www.lfgss.com/thread16557.html

And that linked me to this supplier - http://www.aluminiumwarehouse.co.uk/Aluminium-Round_Tube/c120_131/index.html

I have the Paterek Rack building DVD. If you want to borrow it, PM me.

Intrigued by such a DVD and awaiting that to turn up, thanks to JJ, along with the materials!

The shiny turned up! Squwee!

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Have you got a drawing of what you are going to make yet? Will it be a rack, as opposed to a basket type shape, i.e. no rails?

Dimensions are - 3mm deep 5 bar cross checked alu plating 400mm x 300mm and 400mm x 100mm

                           2500mm long 1/2" tube with 1/16" sidewalls
                           2500mm long 3/4" channel with 1/8" sidewalls
                           2000mm long 1 3/16" wide 3/16" deep flat bar
                           (why they still seem to need metric AND imperial measurements is beyond me)

You may notice that these seem to be maybe a bit ott for the purpose intended, but I always over engineer anything I do as a prototype, as I can then see what (if any) changes are needed.

When fabricating I think its good practice to over do it and it to last than to under do it and catastrophic failure, death, maiming, or deep psychological scarring to occur, especially when I'm the guinea pig! ;P

How are you planning on attaching everything together?

Have you got a drawing of what you are going to make yet? Will it be a rack, as opposed to a basket type shape, i.e. no rails?

Most of its in my head, t'is the way I do things at first me so when I come across unexpected problems I can still be fluid, but once I have the platform and back plate done I will be able to eye it up in position and measure out what supports are needed where, and will probably draw it up then.

It will be a rail-less rack with holes for bungee cords and the like as a practical platform for carrying things too large to fit in rucksack at first, with probable later addition of a quick release basket/plastic box with holes in it.

How are you planning on attaching everything together?

I'm still deciding that, but currently thinking of a mix of alan key bolts with Nylok nuts to stop them vibrating off, and stick to rivets anywhere I can as a solid fixing (mostly) unaffected by vibration, but as rivets need to drilled out if I need to remove them I will at first also use self threading bolts until I'm satisfied with the design.

That makes sense. Do you have rack mounts on your fork, or are you mounting to the axle like the Cetma/VO racks?

I might buy a drill and have a go myself. Seems like it'll be a lot cheaper

That makes sense. Do you have rack mounts on your fork, or are you mounting to the axle like the Cetma/VO racks?

I might buy a drill and have a go myself. Seems like it'll be a lot cheaper

My steed is a Cinelli MASH, so no, no mounts at all!

I am gonna try a few things for mounting it, there will be axle mounts like the VO rack yes, but that also requires a brake drilling for a metal strap to stop it rotating back or forwards, so possibly an adjustable stem clamp, or rubber lined P-Clamps mounted to upper forks will work.

One thing I will say about having a go yourself is that precision and patience is key to this, also buy extra materials like I have, so that if during fabrication you screw it up, no worries as you still have loads left to try again!
Always double check your measurements, and make sure you have a good full sized hacksaw (no junior hacksaws!) and a few spare blades and a good bastard file.

Have you considered making a frame fitting front rack?

(the 2nd rack on the page) http://www.hembrow.eu/frontrack.html

I have, but as I may want to put a decent weights on it from time to time, I didn't like the mounting system tbh.

Finished cutting and filing the alu plates.

This is something I would like to stress - sharp metal corners and high speeds do not mix well.
If you have an accident sharp corners and edges could well cut through flesh and could cause serious injury to yourself and others.

Use something to mark out the corner radius you want (I used electrical tape) onto the back of the plating, cut off most of it with a hacksaw and file all edges to a nice smooth curve.

I have warned everyone, so will not act like health and safety inspector anymore! ;P

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Have you considered making a frame fitting front rack?

(the 2nd rack on the page) http://www.hembrow.eu/frontrack.html

I have one of those on my Dutch bike, which is in Norfolk and hasn't rolled an inch in a couple of years. It's good - very strong. I should bring it up and stick it on the track bike for commuting. The only problem is that the mount is quite large with the rack removed and it's not the sort of thing you can take on and off easily, even though the rack itself slots in and out in seconds.

Whats the weight on it like Sparky?

Not light, but on the Dutch bike it's a drop in the ocean. It's all fairly solid steel.

Lol!

Thats what I thought.

I'm hoping to keep the weight down as much as possible which is why alu is used for material, plus its easier to work without any welding knowledge.

I've had people sit on that front rack. The rear is even more solid. I once carried a mate from Covent Garden to Liverpool Street to catch the last train - he had a traumatised look on his face when we arrived.

Were you riding drunk?

Think that would be enough to traumatise anyone!