Bicycle Cargo Wagon

Photographs

Materials:

• 5 pieces of aluminum sheet metal for the wagon box (Free from scrap yard)
- Sizes are 2’x 2’ for base and 1’x 2’ for the four sides
• 2 - 20” bicycle wheels with tires ($64+$32 = $96) (Recommend to use wheels from used child’s bike transporter)
• 1- 6ft ¾” aluminum squared tubing to make the 2”x 1” metal frame (Free)
• 1 metal angled slotted bracket bar, used to connect the wagon to the bike ($8)
• 1 metal T shape bracket piece for the wagon box ($2.40)
• 9- ¼”x 1 1/2” bolts ( $1.44)
• 9- ¼”nuts and ¼” lock washers ($1.35)
• 1- Clamp, already on the bike used to hold rear reflector

Process:

We were able to acquire pieces of scrap aluminum, and weld them together to create a strong, light weight box. Initially we tried to utilize two bike wheels from an abandoned bike, but deduced that it would be too difficult to adapt to our project. Plus, we wanted to make sure that the cargo system would be sturdy. We decided to order two 20” wheels from a local bicycle shop, which turned out to be our most expensive purchase for $60.00. The wheels were from a child transporter, and we recommend that if you were to build this cargo wagon yourself, that you search for used child cargo systems, and use the parts and wheels for your project. After the fact, we were able to find on www.craigslist.com, used child transports carts for about $20-$25.

After we finished the aluminum box, we built a 2’x 1’ frame made of ¾” aluminum square tube. Again these pieces were given to us as scrap. (For those of you that can’t weld, we recommend that you get together with your local Junior College Weld class, and ask the teacher if any of the students can weld your parts.) We were able to visit the College of San Mateo Welding technologies class, and were able to use the welding skills of the students in the class, for free. After the frame was made, we bolted it to the aluminum box. We inserted the wheels into each end of the frame, and locked them into place with nuts and bolts. At the front of the cargo wagon, we bolted the T-Bracket. We then screwed on the angled bracket bar to the bike, by using the existing nut and bolt that hold the rear wheel into place. We secured the angled bracket by using the clamp. We then bolted the angled bracket from the bike to the tip of the T-Bracket on the front of the wagon.