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Welding a hardcore bike trailer axle

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Welding a hardcore bike trailer axle

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Old 07-25-08, 10:56 AM
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HandsomeRyan
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Welding a hardcore bike trailer axle

Below is the process I used to weld an axle for a future bike trailer. The wheels are 10" pnumatic "hand truck" style tires. I know 10" is a little small but they are rated to 300lbs and they were <$5 each so I think I can make them work. Using wheels rated to 300lbs made me want to build an axle that could match that type of load. I decided to use a piece of scrap 3/4" square steel tubing with axle bolts welded into it.

First I cut a 16" piece of square steel tubing with my metal cutting chop saw. Next, I ground most of the surface rust off the piece of tubing and coated it with a chemical that turns the remaining surface rust into black primer. I got some 5/8" by 7" bolts and cut the heads off of them as well. I drilled a few holes in the ends of the tubing to allow me to tack weld the bolts to the square tube.


I didn't get a picture of the bolt before I cut it.


Here is a shot of the bolt in place ready to be welded.


Here it is after tack welding in place. Because there is almost no tension pulling the bolts outward, even the 6 little tack welds I used was overkill for holding everything in place.


Here is the axle after grinding the welds smooth.


And another coat of rust-to-primer solution has been applied making sure to mask off the threads so the lock nuts that hold the wheels in place will work correctly.

Total cost:
2 wheels @ Harbor Freight- $5 each
2 Bolts- $2 each
2 Lock Nuts- $0.60 each
16" piece of 3/4" square steel tube from scrap pile- $free

Total- <$11

My welder is my most-favoritest tool in the whole garage. I can burn myself, blind myself, and electrocute myself, all with the same tool. Sometimes I make useful stuff like this though.
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Old 07-25-08, 12:45 PM
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dscheidt
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You might be surprised about how much side load you get on the wheels. My oxy-acetylene tanks are on wheels like that, with axles made more or less like yours. (I I used plain rod and cut threads on them, because I had the rod and it's cheaper than buying bolts....) ONe of the axles came loose pulling it around on the gravel. I ended up running a bead around the whole bolt/tube intersection.
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Old 07-25-08, 04:39 PM
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Originally Posted by HandsomeRyan View Post
My welder is my most-favoritest tool in the whole garage. I can burn myself, blind myself, and electrocute myself, all with the same tool. Sometimes I make useful stuff like this though.
maybe there should be a group buy on welders......so far I havn't found an even close to semi significant other justfyable project for getting one
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