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Made A Front Rack This Morning

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Made A Front Rack This Morning

Old 12-17-08, 03:59 PM
  #1  
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Made A Front Rack This Morning

Did it out of 1/4 in brake tubing. Cost about four dollars for the tubing. For heat I used a MAPP bottle (not the whole thing (bout 10$)) and flux coated rods(4$). Just bent everything by hand. The rack top has its inconsistencys but it feels sturdy. I wouldn't put panniers on it. I also managed to burn the snot out of myself. The black thing is a penny, for reference. This was my first time brazing. I have gas welded and I know how to MIG and TIG weld, nonetheless it is a little different. Especially without a oxy acetylene setup. Enjoy.
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Old 12-17-08, 04:03 PM
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holy smokes that's awesome. you oughta rattle can it real quick, it'll look that muc nicer
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Old 12-17-08, 04:05 PM
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Looks like Nitto and Tubus have some competition.
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Old 12-17-08, 04:31 PM
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Looks like you did battle, Yeaouch! Great looking rack though, wish I knew how to braze (and had all the equipment).
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Old 12-17-08, 04:38 PM
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Nice job. I enjoy seeing the homemade stuff.
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Old 12-17-08, 04:51 PM
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smovlov,


What did you use at the mounting points on the fork?
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Old 12-17-08, 04:57 PM
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Originally Posted by twodeadpoets View Post
Looks like you did battle, Yeaouch! Great looking rack though, wish I knew how to braze (and had all the equipment).
If you have a vice, assorted hand tools and about 35 bucks you can do it.

Hacksaw
round file
flat file
torch
hammer
tubing
rods
one bolt and nut for the fork crown

I think that's it. Youtube brazing and figure it out. Its really not that hard.

I watched this for a while to see what was going on then did a few practice brazes. Its really hard to get it as hot as he does in the video as he has an oxy acetylene rig.
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Old 12-17-08, 05:02 PM
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Originally Posted by spinnaker View Post
smovlov,


What did you use at the mounting points on the fork?
The low rider mounts. That's if I understand your question correctly.

Thanks for the replys.
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Old 12-17-08, 06:33 PM
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Originally Posted by smovlov View Post
The low rider mounts. That's if I understand your question correctly.

Thanks for the replys.

No I mean on the rack itself. What do you have at the end of the tubing to attach it to the fork?
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Old 12-17-08, 07:13 PM
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Hey, that's really nice -I love it when people do stuff like this. I have a couple of questions:

1. how sturdy is it? (reason I ask it that I understood strong brazing requires higher temps than a cannister blow torch can supply)

2. what's brake tubing?

3. what kind of brazing rods did you use?

I know many people like low rider racks, but personally I find my bike very well balanced with a front handlebar bag and sleeping bag and tent on a front high rack (like yours) as well as my rear panniers. Seems like there isn't much of a choice for a cheaper front rack, and this looks very neat.
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Old 12-17-08, 07:42 PM
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smolov, thanks for the link, I'm on it! ;-)
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Old 12-17-08, 08:45 PM
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Originally Posted by spinnaker View Post
No I mean on the rack itself. What do you have at the end of the tubing to attach it to the fork?
I just pinched about 1/2 in of the tubing in the vice then drilled it out. I had a feeling i didnt answer you question correctly...

Originally Posted by Nigeyy View Post
Hey, that's really nice -I love it when people do stuff like this. I have a couple of questions:

1. how sturdy is it? (reason I ask it that I understood strong brazing requires higher temps than a cannister blow torch can supply)

2. what's brake tubing?

3. what kind of brazing rods did you use?

I know many people like low rider racks, but personally I find my bike very well balanced with a front handlebar bag and sleeping bag and tent on a front high rack (like yours) as well as my rear panniers. Seems like there isn't much of a choice for a cheaper front rack, and this looks very neat.
1. I have yet to put major weight on it but, vertically it seems very stable. I think laterally (left to right, not back and forth) there is potential for the rack struts to be bent out of shape as it is light gauge tubing. With having such little usable surface area I think it will be a non issue. I'm planning on strapping either my sleeping bag on there or my tent. Both of which will be lightweight. As for the torch temps, the MAPP gas is not like a propane torch. It heats faster and is more suited twoards brazing. From the Bernzomatic website, Propane flame in regular "air" is 3450deg F. the MAPP flame for the same is 3600deg F. The MAPP heats much faster though. The package for the rods says 1650deg F I think.

2. Sorry, I should have been more clear, brake line tubing as in hydraulic brake lines. It is readily available at any auto parts store and VERY easily bent. That's why I don't think the rack would stand up to any major lateral stresses as it would shift from left to right.

3. There is a photo of the Brand and type of rods. They're Bernzomatic flux coated bronze rods. I bought them at The Home Depot for around $4.00. There were 4 rods in a pack and it took a little less than one rod to do this rack. I also did some practice with the same rod. I'm down to about four inches.

I tried to break the practice brazes with my hands and came out a looser. I would imagine that with a hammer and a vice it would be a different story. We're not really talking about those kind of forces for a rack to carry small things.

I also just realized I left out the little stop thing you see on so many racks. Ill have to tag one of those on there tomorrow.



Thanks for all the comments.
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Old 12-18-08, 12:18 AM
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Oh, let us see the rest of that Nishiki. The front end looks really beautiful!
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Old 12-18-08, 12:23 AM
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I really like your project; thank you for sharing.
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Old 12-18-08, 06:41 AM
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wow that's awesome thanks for sharing.

I have some interest into brazing a rack. And your approach is tempting... 35$ plus tools eh? I had no idea you could get a small torch like that
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Old 12-18-08, 07:46 AM
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Does this mean you're building a frame next...?
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Old 12-18-08, 07:50 AM
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Cool project. Brake tubing seems like it would be pretty flexible, but it is readily available. Let us know how it holds up.
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Old 12-18-08, 08:46 AM
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So is it OK if I refer my wife to your screen name when I start churning out rack protypes in the garage by the dozens in my never ending search for the perfect rack?

Nice project, and quite thought provoking.
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Old 12-18-08, 10:01 AM
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Originally Posted by Nigeyy View Post
1. how sturdy is it? ...

2. what's brake tubing?

...
Those were my questions as well. Sure looks nice, though!
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Old 12-18-08, 10:02 AM
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Originally Posted by neilfein View Post
Does this mean you're building a frame next...?
The thought has crossed my mind many times since i was around 15 and into BMX (I'm 22 now). Ive kind of looked into it but it takes a little bit of cash then i would need to build it up and i think might become a money pit for me right now. I have been looking for an oxy acetylene rig on Craigslist though.

And speaking of framebuilding, velonomad builds frames with the same bottled gas, here's a link. He is more or less the go-to guy for any information on this subject (MAPP gas brazing or otherwise).

Originally Posted by staehpj1 View Post
Cool project. Brake tubing seems like it would be pretty flexible, but it is readily available. Let us know how it holds up.
CHEAP TOO! I couldn't believe it. I think I got 16ft for 6 bucks. It really does bend easily though. I got the idea from this guy. His bent I think shortly after but the intended load was MUCH larger than what ill ever be carrying. Prototypes and practice excellent, production probably not so good.

There is some other good rack building information here. About halfway down there are some links and some email correspondence from Capricorn cycles. He has a VERY cool rack.


More photos...

txvintage, if it gets you building things in your garage you direct your wife towards me. Ill take a beating for the sake of DIY rack building.

Thanks again everyone!
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Old 12-18-08, 02:06 PM
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Originally Posted by smovlov View Post
txvintage, if it gets you building things in your garage you direct your wife towards me. Ill take a beating for the sake of DIY rack building.
Ah, the more descriptive statement would be "Gets me building something else in my garage", lol.

I hadn't considered brazing without a mixed gas set up. Simplicity is the answer more often than not.

Now, I wonder if I can braze aluminum, lol.
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Old 12-18-08, 03:18 PM
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Actually,you can braze aluminum! It's done all the time in the HVAC world.
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Old 12-18-08, 07:03 PM
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Originally Posted by Booger1 View Post
Actually,you can braze aluminum! It's done all the time in the HVAC world.
Excellent!
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Old 12-18-08, 10:35 PM
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That looks awesome, wish I could do this!
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Old 12-18-08, 11:48 PM
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Originally Posted by txvintage View Post
Now, I wonder if I can braze aluminum, lol.
https://www.youtube.com/watch?v=QBkF_3Uzirg Thats right... Butt Soldering!

I've used a product like this before and it works. I don't know how, but it works. the key is cleanliness.


I have photos of the whole bike and painted rack and will be posting those soon. Sometime tomorrow I suppose. Plus I added the little back loop. It looks pretty good.
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