Utility Cycling - Coroplast Boxes

OK, "Coroplast" is a trademark, it refers to a kind of Corrugated Plastic. (It's a lot like Corrugated Cardboard, but it's plastic, so it doesn't disitegrate when it gets wet.)

Let me see if I can post photographs, which I took yesterday, 31 October, 2009:
Side View:
http://i134.photobucket.com/albums/q119/hotbike/20_18A.jpg
Quarter On:
http://i134.photobucket.com/albums/q119/hotbike/21_19A.jpg
Rear:
http://i134.photobucket.com/albums/q119/hotbike/19_17A.jpg

Good, those photo's seemed to have uploaded correctly.

The boxes are made of Corrugated Plastic, which I got last year by ripping down political campaign signs the day after Election Day

(NOTE: Election Day is getting near, if you need coroplast, wait until the day after the election , and do what you have to do, with a pair of pliers, or a nail puller. Helps if you have a van.)

The Corrugated plastic was free, but the reflective tape was about three dollars a foot. The reflective tape is at the bottom corners of the boxes.

The Mounting Bracket that holds the front box in place is recycled from the previous bicycle basket, which was made of wire mesh, but ripped. There is also a piece of thin aircraft plywood on the bottom,which abuts the stem, so the basket doesn't droop.

More Photos-

Overhead View:
http://i134.photobucket.com/albums/q119/hotbike/22_20A.jpg

Riders View, showing that REAR VIEW MIRROR:
http://i134.photobucket.com/albums/q119/hotbike/23_21A.jpg

Outside, in a parking lot:
http://i134.photobucket.com/albums/q119/hotbike/05_3A.jpg

In the Train Station Parking Lot:
http://i134.photobucket.com/albums/q119/hotbike/06_4A.jpg

Remember, you might be able to get some free coroplast , the day after elections. You'd be doing them a favor, since there's a law requiring the signs to be down within 36 hours after the election (Check your local laws, and do it early in the morning).

PS-What do you all think of the location of the water bottle cage? On the side of the front box.
Very handy, always within reach.

Nice and what a clever way to recycle. Unfortunately, no one uses coroplast for political campaign signs where I live (the economy isn't robust enough here for it). Hopefully, others will be able to follow your lead.

Can also check at your local sign shop if they have coroplast and/or reflective vinyl offcuts. I work at one, and there's no way to recycle coroplast in our city, so we toss out a lot.

We get a lot of coroplast around here, between political candidates and real estate open houses.:D

I have seen fenders made out of them, as well as skirt/coat guards. My favorite was the comment was from the one guy that was using them as fenders, he commented on getting even with the mudslingers by putting them face down where they would get covered in REAL mud.:lol:

Aaron:)

We have a big problem with get-rich-quick schemers (mortgage modification, "the Secret," etc...) illegally posting signs at intersections and coroplast is becoming popular.

I spotted a city worker with a pickup truck bed full of signs he'd pulled out one afternoon and asked if I could have a few. He told me to take as many as I wanted and encouraged me to grab them from the side of the road whenever I need them. Looks like there's an inexhaustible supply in my city.

Good idea and thanks for pointing out the bottle cage.

To make fenders, push a stiff wire, like a straightened out coat hanger, through one of the channels and bend to desired shape.

Good idea and thanks for pointing out the bottle cage.

To make fenders, push a stiff wire, like a straightened out coat hanger, through one of the channels and bend to desired shape.

Yes, I thought I should point out the small detail of the water bottle cage, a number of people ooh-ed and aah-ed when they saw it. It's in an easy place to reach.

And thank You, for the tip about a stiff wire. A number of small real-estate signs are secured that way, with wire a little thicker than a coat hanger. The wire is driven into the ground to hold up the sign. Now I will take a closer look at those signs, I thought the coroplast was too small to be useful, but if the wire is just the right size to fit between the ridges of the coroplast, I may recycle.

"Cycle and Recycle" - Environmentalist Motto

Another possible source for sometimes rather large coroplast signs is to check with your local convenience stores about their outta date cigarette signs...they're large and usually you can get one for free (also,for those of us that still own cars and have gravelled driveways,when you have to crawl under the nasty beastie,laying on these is so much easier on the back than pointy gravels :twitchy:).

I made a few 5-6 years back after reading an article somewhere online by Kent Peterson (I think),back when we lived in town and I could feasably use my bike more for errands...I dunno what I ever did with em (still have the Monocog I used em on)...I remember taking em off when I realised I was 20 miles to the closest grocery store here and wouldn't be able to errand the bike for more than the diner,convenience store or post office (the only 3 things within what I'm able to bike to due to geography and injuries-which act up when on the bike for long trips loaded).

How did you bind yours together? I remember the article using zip ties,or leather straps or what-not...I used zip-ties,but I also used a hot glue gun to help seal em. Those things were really neat,handy,usable and...loud when not lined or fully loaded,LOL! You're making me wanna go make aonther one :D

Another possible ....

How did you bind yours together? I remember the article using zip ties,or leather straps or what-not...I used zip-ties,but I also used a hot glue gun to help seal em. Those things were really neat,handy,usable and...loud when not lined or fully loaded,LOL! You're making me wanna go make aonther one :D

I started with zip ties, but they broke, and I replaced them with #16 gauge galvanized wire.

Another use for coroplast is mixing cement. When I did some repairs to the basement floor, I mixed the sakrete on a sheet of coroplast. It's still in the basement, under the stairs, I was going to throw it out, but the tenant said she likes it, so I left it there.

Kool,thanks for the tip on the wiring. Yeah,the first couple times I built one,the zipties broke. They held OK with the hot glued joints back-up,but I don't remember haulling any real weight in em.

I can see mixing cement on em! I never woulda thought of it tho,LOL! :roflmao2:

coroplast has been used in the world of R/C gliders/electric power, for sometime.
(google search, mugi, coroplast)

double sided tape is good to use.
something like double sided carpet tape
hot glue gun
office stapler
a solid long straight edge

infinite usages.

you can seriously geek out on coroplast.
sandwich foam between layers...
the way you fold it
glue it
tape it
staple...

I've made a lot of things out of coroplast, laptop carrying case?

it goes on and on and on

I hadn't thought of that (the RC world),but now that you mention it...:)

I first saw/heard about this stuff for bike use reading something (mighta been a blog,I don't remember) by Kent Peterson,he'd made some really nice boxes and fenders outta this stuff. Now that I have my old Monocog back together and setup for some light "utility biking",when I find a better rear rack (I have a SP clamp style,it's sways with the pedal strokes,so I never use it),I'd like to make some "saddle-bag" type boxes to go on it :thumb:

I hadn't thought of that (the RC world),but now that you mention it...:)

I first saw/heard about this stuff for bike use reading something (mighta been a blog,I don't remember) by Kent Peterson,he'd made some really nice boxes and fenders outta this stuff. Now that I have my old Monocog back together and setup for some light "utility biking",when I find a better rear rack (I have a SP clamp style,it's sways with the pedal strokes,so I never use it),I'd like to make some "saddle-bag" type boxes to go on it :thumb:

You have a Redline Monocog? I had a Redline Monocog, but it was awed in half with a hacksaw. Somebody must've been trying to build a custom bike and gave up. I have some parts for the Monocog, let me know if you need anything for the Monocog. No, wait, I think I only have a rear wheel and the cranks, the brakes went on the bike in these pictures. The front wheel was rebuilt with a Sturmey Archer 3 speed hub, and I put that on another bike.

You have a Redline Monocog? I had a Redline Monocog, but it was awed in half with a hacksaw. Somebody must've been trying to build a custom bike and gave up. I have some parts for the Monocog, let me know if you need anything for the Monocog. No, wait, I think I only have a rear wheel and the cranks, the brakes went on the bike in these pictures. The front wheel was rebuilt with a Sturmey Archer 3 speed hub, and I put that on another bike.


Small world,eh? :p:thumb:

I was having trouble coming up with a stem,mostly,but I found one I thought I'd gave to a Bud. Musta not have given it,huh,LOL! I have a pair of extra hubs,somewhere. The brake cables are a little worse for wear,but they'll service till they won't,LOL! I've had this one for years,it's seen duty as a rigid mtn bike,a commuter/roadie,Fox fork suspended mtn bike,and now back to a errand bike. I guess I'm car-lite right now,by breakdown more than by choice,but I'm not in a big hurry to fix the old Wagon anyways. I can always drive my wife to work and keep her car if I really need one that bad,LOL!

how about a Hawk Box?
http://virtualvideo.cc/falconry/coroplast.html

coroplast

you can also use clear coroplast
and insert LED's to the "flutes"

http://www.mugi.co.uk/media_movies.php#
see "Mugi Morphin"
scroll down about 1/2 way

Kool!!!!

How long do they last in general use?

How long do they last in general use?

Depends if you use a single layer (of coroplast) or double it up. Make the second layer with the flutes going at a right angle to the first layer.

The rear of the front box in the pics is actually three layers, and the mounting hardware is from a wire-mesh basket (which broke).

The first week of the rear boxes, I hit the left side box with my foot while dismounting, and tore the coroplast, with the direction of the flutes , so I made a patch with the patch flutes going horizontally, it's held up ever since. I have a lot of coroplast, so it doesn't really matter if I have to re-do it.
I think sunlight is the killer of coroplast, the UV light will make the plastic disintegrate, but I keep mine indoors.

Did anyone heed my advice and gather up some coroplast the day after elections , this year?

Nice work!

Now, I'm a big fan of can-do, DIY kind of action ... but, dang, man, show some pride!

Riding around with Coro baskets and such ... I dunno.

I don't think this is how to win girls.

Maybe you could rattle-can those white uglies in black, then glaze of some flames ...

Nice work!

Now, I'm a big fan of can-do, DIY kind of action ... but, dang, man, show some pride!

Riding around with Coro baskets and such ... I dunno.

I don't think this is how to win girls.

Maybe you could rattle-can those white uglies in black, then glaze of some flames ...

I'm not trying to "win girls". I have a 27 year old Daughter, one's enough. This is her bike, BTW.

I'm trying to save some money by using coroplast instead of fiberglass. Did you see the other bike, which my Daughter designed?

Do a search for "Fiberglass Ladies Bicycle".

here's a funky thread
http://www.rcgroups.com/forums/showthread.php?s=&threadid=145766&highlight=box

I've made all sorts of coroplast "things"
you'll geek out
along with Duct-tape wallets
http://www.google.com/search?client=safari&rls=en&q=duct+tape+wallet&ie=UTF-8&oe=UTF-8

duct-tape-panniers?
messenger bags out of plastic bags?
http://www.youtube.com/watch?v=sB1mE8e35UY

Okay, I got a digital camera for Christmas! A Canon SD1200 IS, ten megapixels. I will now attempt to document the installation of another set of Coroplast Panniers, on the Lowrider "Type 10"-

http://s134.photobucket.com/albums/q119/hotbike/IMG_0006.jpg

this is in front of a mirror.

http://s134.photobucket.com/albums/q119/hotbike/IMG_0007.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0008.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0009.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0010.jpg

This is a test of the new 10 megapixel camera...

I have separated the pannier boxes from the rack, to show how they are constructed. The rack is a set of half inch by three quarter inch steel rubes, secured to the fiberglass monocoque by three five inch bolts with fender washers.

http://s134.photobucket.com/albums/q119/hotbike/IMG_0011.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0012.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0013.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0014.jpg

I only have some packing tape holding the boxes to the rack! they are held down by gravity, and the front is tucked under the rear of the seat.

For Christmas-and in exchange for allowing him to buy a Subaru that was being held for me-my Dad gave me his 2nd owner 80,937 mile old 1999 KIA Sportage 2 door/soft top. He owned it for a few years,but used it mainly to tote his garbage trailer around his 47 acres/workshops,hence no need for back seats. So,he removed everything from the backseat/cargo area,and made a "wall" out of a single piece of a large coroplast sign. Worked really well,and sealed pretty tight with duct tape :thumb::roflmao2: Of course,I won't be pulling a trash wagon,and I have 2 kids (7 and 12),so I'll be reinstalling the backseat,belts,roll-bar,and carpeting (as early as this coming weekend). Here's a pic as it sits today (I was making patch panels for the rust you may notice). :D

http://i722.photobucket.com/albums/ww227/Longhaultruker1/My%201999%20Kia%20Sportage/Reararea1.jpg

Nice ride!


Okay, I got a digital camera for Christmas! A Canon SD1200 IS, ten megapixels. I will now attempt to document the installation of another set of Coroplast Panniers, on the Lowrider "Type 10"-

http://s134.photobucket.com/albums/q119/hotbike/IMG_0006.jpg

this is in front of a mirror.

http://s134.photobucket.com/albums/q119/hotbike/IMG_0007.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0008.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0009.jpg

http://s134.photobucket.com/albums/q119/hotbike/IMG_0010.jpg

This is a test of the new 10 megapixel camera...

For Christmas-and in exchange for allowing him to buy a Subaru that was being held for me-my Dad gave me his 2nd owner 80,937 mile old 1999 KIA Sportage 2 door/soft top. He owned it for a few years,but used it mainly to tote his garbage trailer around his 47 acres/workshops,hence no need for back seats. So,he removed everything from the backseat/cargo area,and made a "wall" out of a single piece of a large coroplast sign. Worked really well,and sealed pretty tight with duct tape :thumb::roflmao2: Of course,I won't be pulling a trash wagon,and I have 2 kids (7 and 12),so I'll be reinstalling the backseat,belts,roll-bar,and carpeting (as early as this coming weekend). Here's a pic as it sits today (I was making patch panels for the rust you may notice). :D


Merry Christmas! Nice SUV.:rolleyes: Let's keep it about bikes, eh?

Ummm....it was never about bikes,but about coroplast,methought...hence the name of the thread "COROPLAST boxes"? But yeah,this is BIKE forums :thumb:

Haha, sorry. Thanks for not taking offense. I'm sort of anti-car, but that didn't stop me from accepting car rides to the ski hill twice last week!

Haha, sorry. Thanks for not taking offense. I'm sort of anti-car, but that didn't stop me from accepting car rides to the ski hill twice last week!


Nope,no offense taken :thumb:
I'm actually sorta aniti-car myself,I just don't live in an area where non-car-ownership is very feasible (especially w/ 2 kids)...but hopefully that will change in the next year or so :D

Good, those photo's seemed to have uploaded correctly.

The boxes are made of Corrugated Plastic, which I got last year by ripping down political campaign signs the day after Election Day

(NOTE: Election Day is getting near, if you need coroplast, wait until the day after the election , and do what you have to do, with a pair of pliers, or a nail puller. Helps if you have a van.)

The Corrugated plastic was free, but the reflective tape was about three dollars a foot. The reflective tape is at the bottom corners of the boxes.

The Mounting Bracket that holds the front box in place is recycled from the previous bicycle basket, which was made of wire mesh, but ripped. There is also a piece of thin aircraft plywood on the bottom,which abuts the stem, so the basket doesn't droop.

More Photos-

Overhead View:
http://i134.photobucket.com/albums/q119/hotbike/22_20A.jpg

Riders View, showing that REAR VIEW MIRROR:
http://i134.photobucket.com/albums/q119/hotbike/23_21A.jpg

Outside, in a parking lot:
http://i134.photobucket.com/albums/q119/hotbike/05_3A.jpg

In the Train Station Parking Lot:
http://i134.photobucket.com/albums/q119/hotbike/06_4A.jpg

Remember, you might be able to get some free coroplast , the day after elections. You'd be doing them a favor, since there's a law requiring the signs to be down within 36 hours after the election (Check your local laws, and do it early in the morning).

I made a two-minute video on how to make one of these Coroplast Boxes, for the Handlebars.

http://www.youtube.com/watch?v=Rrq0lHO67u4


http://www.youtube.com/watch?v=Rrq0lHO67u4

My Carradice bar bag is made from a coroplast box covered in canvas. The box is joined by metal rivets as is the Rixen and Kaul mount.
The rear panniers have a coroplast base and back internal stiffening plate. The base is rivetted to some plastic feet and the back is rivetted to an aluminium mounting rail and a plastic anti-sway rail.
I've had both bags since 1996 and they have had a lot of use.

If you want to use corroplast as stiffening, I would suggest that you round off the corners to avoid stressing the canvas, this will give you an extra decade or 2 of extra use.

My Carradice bar bag is made from a coroplast box covered in canvas. The box is joined by metal rivets as is the Rixen and Kaul mount.
The rear panniers have a coroplast base and back internal stiffening plate. The base is rivetted to some plastic feet and the back is rivetted to an aluminium mounting rail and a plastic anti-sway rail.
I've had both bags since 1996 and they have had a lot of use.

If you want to use corroplast as stiffening, I would suggest that you round off the corners to avoid stressing the canvas, this will give you an extra decade or 2 of extra use.

I'm happy with the bare Coroplast. But I was unaware that some cloth panniers were made with Coroplast stiffeners, thanks for informing me.

Rivets? Rivets cost more than the Coroplast. I make two holes an inch apart and run a zip-tie though them, using a brake cable tool to do the final tightening of the zip-tie.

I've been thinking about rounding the corners, but I think, maybe they can be heated with a propane torch, to melt and soften the plastic, and smoothed with some kind of tool? I would want to do this outdoors, in case the thing ignites...have a bucket of water handy.

I've been thinking about rounding the corners, but I think, maybe they can be heated with a propane torch, to melt and soften the plastic, and smoothed with some kind of tool? I would want to do this outdoors, in case the thing ignites...have a bucket of water handy.

you might have better control and results by boiling water in a large container and heating the coroplast in that manner.

you might have better control and results by boiling water in a large container and heating the coroplast in that manner.

Have you tried that method? I've never heard of that technique.

I've been thinking about rounding the corners, but I think, maybe they can be heated with a propane torch, to melt and soften the plastic, and smoothed with some kind of tool? I would want to do this outdoors, in case the thing ignites...have a bucket of water handy.

You can bend it with a hot air gun and patience, but you can't really press it into shape or over a mold. If you smooth it into shape or get it too hot you wind up collapsing the splines, or at least I do.

I've found complex curves - bending around more than one axis - impossible without causing the plastic to crease.

Very cool way to recycle and save some dough while adding load capacity to your bike!

http://i134.photobucket.com/albums/q119/hotbike/IMG_2744.jpg

I cleaned up after the Hurricane (Sandy). Got a few more boards of Coroplast (corrugated plastic), a week after the election.

But I have seen no demand for Bicycle Baskets this year, and in an effort to help clean up after Sandy, I made some waste-baskets.


http://www.youtube.com/watch?v=a0rq9nm2-Vs

A lot of the signs were taken down this year, and with the mess left by the Hurricane, I could not get them any sooner. Power at my Mother's house was out for two weeks, and my power was out for one week.

Coroplast is great! I built a tailbox for my old Linear recumbent bike (http://drumbent.com/tailbox.html) many years ago (I sold the bike to a friend a while back. The box is still on it, and while it has become a bit tattered it's still working after over a decade!). I also use coroplast to make strong, lightweight boxes for carrying some of my music gear, because that stuff also mostly gets carried by bike and the usual heavy instrument cases are, well, heavy!

Mark