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Old 04-13-10, 03:16 PM   #1
Dan Burkhart 
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Big Dummy racks DIY

Well, after much procrastinating, and shifting project priorities, I finally got a start on making my Big Dummy useable.
Trying the DIY route, just to see how it turns out. 3/4" EMT conduit is the perfect size tubing for this, so here we go.
First, create a layout table, marking the angles and dimensions as found on Extracycle's open source documents.

Then, start bending the conduit, checking angles as you go.


Test fitting the tubes.

Zip tied two panniers on one side just to try it out for size.

So far so good.

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Old 04-13-10, 05:23 PM   #2
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I have wanted to try this. More progress pics will be eagerly anticipated.
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Old 04-13-10, 05:33 PM   #3
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I have wanted to try this. More progress pics will be eagerly anticipated.
I'll post as I go, but there will be no progress for the next week as I'll be on the road.
I'm not sure I'm satisfied with this set. I may be doing a re-do.
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Old 04-14-10, 09:06 AM   #4
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Man, you are going to haul some stuff!

Good luck with this -- I enjoy these DIY posts.
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Old 04-17-10, 07:31 AM   #5
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Dan-

Out of curiosity, about what were you dissatisfied with your first go?

Eric
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Old 04-17-10, 07:03 PM   #6
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Dan-

Out of curiosity, about what were you dissatisfied with your first go?

Eric
Well, I tried to make multiple bends at the rear so they would look more like factory than a simple bend. I didn't get the two of them to match as well as I'd like, and it is noticeable, to me at least.
I think I'll call this a practice set, and make the next pair with a simple bend.

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Old 04-27-10, 10:36 AM   #7
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OK, I finally managed to grab a bit of time today to make up a second set. I gave up on the idea of trying to copy the profile of the factory originals, and came out with a much better result, and a matched pair.


To fit properly in the rear tube requires a small cutout to accommodate a small obstruction where two tubes join.

I'm much more satisfied with the result this time.


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Old 04-27-10, 02:10 PM   #8
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Looks good. What's the wall tickness of the conduti you're using, and what do you think they'll hold?
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Old 04-27-10, 02:51 PM   #9
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Looks good. What's the wall tickness of the conduti you're using, and what do you think they'll hold?
It's standard EMT, wall thickness is about .05" which makes it 18 gauge. I imagine it'll hold anything I can pile on it and still pedal, doncha think?
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Old 04-27-10, 06:29 PM   #10
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Buy those RANS panniers. Nothing will fall out of them - the ones made for their RAC system. They should be compatible with your BD setup.
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Old 04-29-10, 01:42 AM   #11
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Nice work Dan, much more better than the first one. When are you going to finished up with your whole work ? I am really excited to see what is the next thing you are going to do. I am also thinking to give a try like you but doesn't seems that I am good like you.
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Old 04-29-10, 02:40 AM   #12
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Nice work Dan, much more better than the first one. When are you going to finished up with your whole work ? I am really excited to see what is the next thing you are going to do. I am also thinking to give a try like you but doesn't seems that I am good like you.
Thanks. All it takes is a bit of patience,and the conduit is cheap, so screwing up the first try is not a disaster. The costliest part is the conduit bending tool, but you may be able to rent one at a rent-all store.
As to when I'll finish, hard to say. Got a lot of other stuff going on right now but I'll work on it as I can.
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Old 04-29-10, 04:18 AM   #13
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are you using steel or aluminum conduit?
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Old 04-29-10, 06:05 AM   #14
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are you using steel or aluminum conduit?
Steel.
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Old 04-29-10, 05:33 PM   #15
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Are you going to make some wideloaders?
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Old 05-01-10, 06:42 AM   #16
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Thanks. All it takes is a bit of patience,and the conduit is cheap, so screwing up the first try is not a disaster. The costliest part is the conduit bending tool, but you may be able to rent one at a rent-all store.
As to when I'll finish, hard to say. Got a lot of other stuff going on right now but I'll work on it as I can.
Better than renting is find an electrician who isn't using then on the weekend. I have made a handful of projects borrowing my buddies benders on the weekend.

They look good.
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Old 05-03-10, 03:46 PM   #17
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Are you going to make some wideloaders?
Yes I will.
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Old 05-03-10, 08:16 PM   #18
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I just ordered a Big Dummy frame to build up, and I had been planning on making my own rack system for it as well. It's good to see I'm not alone in my planning. That must make it a good idea! You're racks are very similar to what I was planning, and I'll be interested to see how yours turn out, as well as how mine come out as well. I'm planning on making mine able to work with panniers first, with bars built in to hang the panniers from and all, and eventually I may go so far as to custom make some larger bags similar to the Xtracycle setup. I was also going to do some wideloaders too, with runningboards on them. I've built racks for my regular bikes, and I usually top them off with a custom made wood deck with some sort of design burned in the top. The Dummy shall be no different.

Frame gets here later this week, and I can't wait!
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Old 05-04-10, 07:39 PM   #19
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I just ordered a Big Dummy frame to build up, and I had been planning on making my own rack system for it as well. It's good to see I'm not alone in my planning. That must make it a good idea! You're racks are very similar to what I was planning, and I'll be interested to see how yours turn out, as well as how mine come out as well. I'm planning on making mine able to work with panniers first, with bars built in to hang the panniers from and all, and eventually I may go so far as to custom make some larger bags similar to the Xtracycle setup. I was also going to do some wideloaders too, with runningboards on them. I've built racks for my regular bikes, and I usually top them off with a custom made wood deck with some sort of design burned in the top. The Dummy shall be no different.

Frame gets here later this week, and I can't wait!
Great. It will be fun to compare our solutions. Looking forward to seeing your work.
I'll try to grab some time to make a bit of progress this week.
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Old 05-19-10, 09:16 PM   #20
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A little bit of progress today. I got My Eco Deck and Magic Carpet.

My frame spreading tool came in handy in the fitting stage,
The Magic Carpet is too small to fit over the Eco Deck.

I've got a workaround up my sleeve for that one though.

I got the stem and handlebar fitted to the seatpost. I'm going to trim the length some. It's kinda wide for little arms.


I managed to get started on the wide loaders, but ran out of time. Hope to finish em up tomorrow, at least the bending stage. The wood deck will take a bit longer.

I took my son in law for a ride on the back, and it handled it with no problem. If it can haul a 200 lb man, a 5 and 3 year old should be able to ride it together.
Hoping I can try it with all 3 of my grandkids this weekend.
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Old 05-20-10, 02:30 PM   #21
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Wide loaders with a twist. Step one.


Step two.

I think I'm going to narrow it down a bit though. I think this is going to be a bit wide.
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Old 05-20-10, 04:54 PM   #22
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This is getting interesting. I think you have keep it no wider than a normal sidewalk or doorway. My Dummy fits through my door with the wideloaders on.
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Old 05-20-10, 07:15 PM   #23
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This is getting interesting. I think you have keep it no wider than a normal sidewalk or doorway. My Dummy fits through my door with the wideloaders on.
Yup. It would definitely be too wide with two at that width.
Also, I think I came up against the limitations of the conduit bender here. I think a tubing bender capable of a tighter radius bend would do a better job for the upright bends.
Can anyone tell me what a fully assembled wide loader kit measures for width?
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Old 05-20-10, 08:52 PM   #24
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Yup. It would definitely be too wide with two at that width.
Also, I think I came up against the limitations of the conduit bender here. I think a tubing bender capable of a tighter radius bend would do a better job for the upright bends.
there is a bender for 3/4 emt that makes a 4" radius bend. (well, just a hair over: NEC says > 4", so they're about 4 1/16".). That's about as tight a bend as is possible cold.
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Old 05-20-10, 09:11 PM   #25
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I measured my Wideloader assemblied on my Dummy:
Rear is 25 1/2 inches
Front is 31 inches
Keep in mind I used a tape measure without a square.
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