Accidental discovery

I suppose many discoveries are accidental. In my previous post, I noted that I was contemplating two different joints for the frame. A notch or a double notch. Turns out that these are called lap joints and they have many variants. and half-lap joints. And, according to good friend, amateur woodworker and all around smart guy, Michael, that the lap joint, especially when secured with a pin or dowel and glue is about as strong a joint as you can make with wood. He noted that you would have grain running in three different directions giving the most strength possible. So, I'm going with it. Lots more work cutting the joints, but it should turn out very nice.

One thing I am realizing, and you have to if you are following the tedium here, is that every corner turned and everything learned results in a delay of the project. Or, if not delay--I have no deadline--then certainly a stretching out to the infinite horizon the end of the project.

Pictured is the "cross-lap joint" in rough form. In final form, the two edges will be flush, the joint glued and will include a dowel or pin.

Testing 1, 2, 3

Between various appointments and grandchild duty, I setup what I hope is the last of the fabrication tests. When you look at the plans, it all seems so simple. A few tools, a vice and a list. Just do things in order and it will all work out. Maybe that's the way it is supposed to work, but for me, it's more experimentation, testing and "lab" work.

Today, I cut some notches in a piece of lumber with the same dimension as the stuff I'm planning to use. I wanted to see what it would be like to actually mill this stuff and put it together. The result? Pretty simple.

Lobnitz says that a notched joint is strong, but a "double" notch joint is not as strong. I'll go with his recommendation. Or, not. Depends upon my desire for a more aesthetic piece, or an aesthetic that is more specific to my interests. This first image is the test piece according to the plans. The next one is what I would prefer, it it were strong enough. More later.

Pedal to the metal

I stopped by The Steel Yard today while running other errands. The ever helpful Lance was there, ready to put the Omada H-4013 to good use. I now have enough metal plates for at least three trailers, though I will have to do some further cutting. Seems Lance was reluctant to put his hand in this gigantic hydraulic scissor machine to get all of the cuts needed.
The experience was a good lesson in "right tool for the job." If you have absolutely no other option, hacksaws will work. But, having someone cut these for you and having plates cut for more than one trailer is not only effective and efficient, but it moves the work along much faster.

The challenge of the hand tool only approach

My experiences using a hacksaw to cut out the towing brackets has made it clear that a different approach might make more sense. In other words, I need some power. Here's why.

It's a noble idea to try to work on this project with just hand tools. And, it's possible if you have the right tools. I thought a hacksaw would be enough, especially with a new, sharp blade, to handle the fairly simple cutting. Not so. A standard hacksaw frame is just too shallow to allow the cuts required. There are probably other frames that would work, but a call to the Temple of Hardware, Winks, confirmed that they don't carry them. I was surprised.

Day of rest

Not really a day of rest, but a day that had many conflicts. At least conflicts with additional fabrication of the trailer. For one, there was Trinity SeniorConnect. Sorry, no website to send you to on that one. It's a program for at-risk seniors in NW Portland. I am a volunteer.

Then, there was a reception for Travel Oregon's launch of their website, Ride Oregon. It's been out for a couple of months, but I had an opportunity to catch up with the folks at Substance. They are the agency who designed and programmed the site.

It was worth the diversion, though I might have stopped along the ride and picked up some saw blades and probably a new saw at Winks. Alas, I did not and I look forward to tomorrow's schedule for a chance to do that and much more.

Fabrication, round one

I finally got my building feet wet today. And, just as I suspected, there's more to this than meets the eye. When you look at the design and directions and the simple line drawings of the tools, all look straightforward. Then, you actually have to get the tools out and go to work. Or, in my case, create some tools to do the work.

Because the sheet of 14 ga. mild steel is much taller than my vice, I needed to create a sort of jig to make the sawing stable. I cut two lengths of scrap bead board and used them to stabilize the metal.

Measure twice

I finally got down to determining how many beams I would need and whether or not the ones I had would do the trick. It's not always obvious. At first glance, I thought I did not have enough lumber for the job. But, as I evaluated the various parts, I realized that I could make the entire trailer out of the four beams that I have. So it is.

Tomorrow, I start the actual fabrication. I'll be cutting out the metal bits. And, I will be adjusting the dimensions provided by Carry Freedom so that the metal parts fit more closely with the wood. You'll see it more clearly as I post pictures.

Wood is good

While this may be titled "Bamboo Bike Trailer Project," it looks like my particular trailer will be built of wood. I discovered, or finally paid attention to, a cache of excess 2 x 2 lumber used for two other projects. As noted in earlier posts, I would endeavor to use what was available rather than purchase new materials.

According to the project plans provided by Carry Freedom, bamboo, steel, and wood are all acceptable or preferable materials. The plans show 2 x 2 lumber being used with a notch cut for added stability. The lumber I will use is fir or pine, I'm not quite sure. It would be better, I think, to be using hardwoods, but this is a somewhat experimental project. Should this wood prove to be too flexible or not strong enough, I can always salvage the hardware bits and use them with other material.

Gauging the steel

Today's lesson involves plate or sheet metal, thicknesses and getting something you can use that does not require special tools or machinery.


I went to The Steel Yard this morning knowing that they sold plate metal, which I'm told is what I'm looking for, in scraps as well as full sheets. A phone call last week was answered by a helpful sales person who told me that 1/8" thickness steel plate, which is what is specified in the plans, would be 10 gauge and it would be very difficult, if not impossible, to bend and shape with only a vice and a hammer. He said 11 gauge would probably work and was not that much thinner.

The spirit of the project, II

Another dimension to the project, consistent with what I hope the results will achieve, is a light environmental footprint. The most direct way to achieve that is to make sure that the acquisition of materials and the construction activity are accomplished without excessive driving, waste or fuel use. To that end, here are some additional constraints:

• Walk, ride a bike or use mass transit to acquire any materials.
• When possible, use hand tools during construction.
• Work during and in daylight to reduce power consumption.
• When building, make the most efficient use possible of the materials.

First steps, material sources

Given the instructions and even the name of the trailer, Bamboo, I thought my first task was to find bamboo. I had a source, Bamboo Craftsman Company just a short ride from the house. I called, but they were not open. Next, I looked at the metal fabrication diagrams. These cover the towing brackets and wheel brackets. I figured the metal I could find at a local hardware store. Not so. There really wasn't anything significant left other than wheels, which I knew I would have to purchase at a local shop.

The spirit of the project

This project, and perhaps others like it that use Carry Freedom's plans, has some guiding principles. In developed countries and in projects where the builder has means like me, there are conditions that should be considered. For example, where do you get your materials? Do you purchase new or used recycled goods? Can you simply "find" the materials you want in the garage or basement or dumpster? Should you rely upon found objects?

The project's purpose

Transportation by bicycle is an old concept, but is only now gaining traction in the United States. In the developing world and in many European countries, bicycles are an essential component of getting to work, to school, buying groceries and carrying goods. (Image from Carry Freedom)

The utility of a bicycle is enhanced by cargo carrying components. For example, racks and saddle bags allow one to carry a limited amount of goods. A trailer, however, greatly expands what might be carried.

With a growing interest in this form of transport, I began investigating bike trailers designed for cargo hauling. Living in Portland, Oregon, exposed me to a number of organizations and individuals using trailers or other modifications to bicycles to transport goods. I finally landed on the Bamboo Bicycle Trailer from Carry Freedom. I was impressed not only with the simple DIY concept, but also the designer's desire to enhance the lives of folks with limited means. He was inspired by a customer using one of his trailers who left it in a Nepalese village where it was used heavily.

The more I thought about the trailer, the more I wanted to build one. I enjoy creating things, though I'm not particularly handy. I do know how to use basic tools and was exposed as a kid to my father's mechanical capabilities. As a car mechanic, he was well versed in the use of tools and understanding how things worked. With that limited background, I downloaded the plans for the Bamboo Bike Trailer.

The longer I thought about the trailer, the more purposeful was my interest. At the risk of being too philosophical, the following sums up my reasons for building the trailer.

• To expand our family's ability to do more on our bicycles including grocery shopping
• To satisfy my interests in building a useful object
• To explore ways in which the bike trailer might be used by others
• To connect with the Portland, Oregon area's growing bicycle community
• To have some fun