Bicycle Box Trailer

Discussion in 'Bicycle Trailers' started by Fabian, Sep 9, 2009.

  1. Fabian

    Fabian Well-Known Member

    Sometimes you have moments of inspiration - turning packing crates into a bicycle box trailer.


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  2. Fabian

    Fabian Well-Known Member

    Last pic

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  3. Esteban

    Esteban Active Member

    Looks good & a useful accessory !
  4. machiasmort

    machiasmort Active Member

    Just a suggestion. If your going to run that thing in the weather? I'd systematically remove the corner supports and run a bead of silicone calk so that water don't get behind it! Rubber blocks under the suspension where it mounts to the frame and rubber insulation strip along the top lip (between lid and body) will add water seal and quiet it drammatically. Thats one killer build! One of the better I've seen!

    That's one awesome trailer!
    Last edited: Sep 10, 2009
  5. Nice trailer. You have given me some ideas. Hmmmm.........
  6. Fabian

    Fabian Well-Known Member

    The trailer is not quite finished.

    I want to add an aluminium carry rack, a set of gas struts for automatic lifting of the lid and a 12 volt, 10 amp lithium battery kit to run trailer brake lights, indicators, reversing lights and a pair of 100 watt driving lights mounted on the front vertical section, adjoing the trailer lid at the hinges.

    The battery kit will also power the brake lights and indicators on the mountain bike and the front wheel will have a high current hub installed for regenerative braking.
    Another concept which i want to adopt is for both trailer wheels to have a high current electric hubs installed with even more power available to the the motorised bicycle setup and to add extra regenerative braking capacity to the system, feeding power back to the battery upon using the brakes.

    This baby is going to be a high-tech - a pusher trailer and a stopper trailer too.
    With electric hubs the possibilty of an anti lock braking system (ABS) becomes a real possibility - this would be the ultimate expression of ingenuity

    I am sure someone else could build an even better, smarter system and i would dearly love for someone to be taken by enthusiasm and """just do it"" - making it happen when everyone else is telling you "it can't be done".

    Motorised bicycling is has humble roots but the quest for a more professional approach to build quality and safe performance is contagious, especially after talking it over with the boys when having one of those garage brain storming sessions that get out of control.

  7. machiasmort

    machiasmort Active Member

    I hope you didn't take me wrong?

    I want to add an aluminium carry rack, a set of gas struts for automatic lifting of the lid and a 12 volt, 10 amp lithium battery kit to run trailer brake lights, indicators, reversing lights and a pair of 100 watt driving lights mounted on the front vertical section, adjoing the trailer lid at the hinges.

    All excellent ideas, so long as you leave room for the fish locator and radar dectector! LOL! Just joking!

    Music is a serious consideration as well as insulating that thing!
  8. machiasmort

    machiasmort Active Member

    Your woodwork is to be admired w/the angles you cut arround the wells!
  9. Fabian

    Fabian Well-Known Member

    Hi machiasmort

    I must admit, i do like the wheel wells myself and i intended to make them an asthetic feature.
    In all honesty, building the wheel wells as a square box section would have been simpler but i wanted something a bit different, it's the way they work so pleasingly on the eye; thing everyone seems to comment on.
    The most difficult part of the build process though was hand filing all the 45 degree cuts on the aluminium sections - i hate gaps and love perfection, but getting those angle cuts perfect was a nightmare, not as bad as the electrical problems i had with my last replacement engine though.

    Cheers Fabian
  10. machiasmort

    machiasmort Active Member

    My thoughts are exactly that, some of the other guy's on this board are brilliant... I pay attention to detail as much as possible tho. Taking in knowledge like a sponge!!! Some smart people on this thing!

    One of our members "Simon" is one of the wiz's for add on's. I hope he'll see it and throw his 2Cents in!

    If you get a chance??? I'd like to see a closer look at how you connected it to the frame of the bike???

    I think it would be cool to make a Pop-up version of your trailer for camping!!! The idea will get your head spinning, I'm sure!!!
  11. Fabian

    Fabian Well-Known Member

    The trailer connection is the standard "Burley" trailer hitch arm and reciever mechanism that comes with any Burley bicycle trailer.

    In my opinion it doesn't look strong enough for my application and the unloaded trailer weight is at the maximum load limit for the hitch mechanism.
    The Burley Tailwagon trailer is rated at around 6 kilos and the maximum carrying weight is 25 kilos.
    I have used the older style Burley Tailwagon base, because i wanted a certified carrier and hitch mechanism.
    The total trailer weight would have to be getting up towards 30 kilos - yes, this thing needs to be lightened being built out of 3/8 plywood for the base and 5/16 plywood for everything else.
    The aluminium sections are 3mm thick (because that was the scrap metal i had access to for free) and it is surprisingly heavy but surprisingly strong.
    If paying for all the materials, i would have built the sides out of 3/16 plywood to save weight and used 2mm thick 40 x 40mm sectional sized angle aluminium instead of 3mm x 60 x 40.
    I suspect the aluminium and screws weighed more than the plywood.

    I'll be getting an engineer to give me advise on designing a bicycle hitch mechanism capable a a maximum load capacity of 80 kilos for a good saftey margin.

    Having said that, i did a test; trailer loaded up with exactly 20 kilos, for an all up weight of around 50 kilos.
    In my area we have a few good steep hills that are reasonably long.
    The SickBikeParts Jackshaft was so impressive. The second steepest hill in my area had the bike towing 50 odd kilos and i didn't even need to get into first gear (my cassette is a Shimano 11-32T) as it was pulling like a train in second gear.
    A total all up towable weight of 60 kilos is a real possibility on steep hills with the new Shimano 12-36T cassette (with the 12 swapped for the optional 11, becoming an 11-36T) and the SickBikeParts Jackshaft working in perfect harmony.

    You can now understand why i want 'trailer brakes' with 50 or even 60 kilos pushing me from behind especially down a steep hill.

    Speaking of towing weight and needing a super low first gear, a company called actiontec does wonderful titanium and also extra hard heat treated titanium cassette gears that you can purchase as individual sprockets, if wanting to create your own gear ratios or a complete cassette with their ratios.
    Click on pricing and ordering numbers and scroll down to titanium cogsets and heat treated titanium cogsets.
    This will blow your mind - how about a 9 speed 11-39T and they say the 39 will work with a standard Mountain bike rear derailleur, because i asked.

    go here:

    or if that doesn't work:

    Cheers Fabian
  12. machiasmort

    machiasmort Active Member

    I'm not feeling real well, lately. Seriously duffed up back. But I'll post some pics of my bike that I have saddle bags in the works for.

    Look up BlueGoatwoods and see his posts on saddlebags.

    You could probably modify his ideas and put a towbar off of a rear bike rack. You would then have three points of contact to the frame.