DIY: Bike Rack

[Grizz]

I finally put a bike rack on my smart car, the pictures are in the gallery under exterior modifications. It was about $200 in materials. Cut, drilled, and tapped out two eye bolts. Bought a rack from my local bike shop, then built a frame to hold it. It is very solid and I didn't have to cut or modify the car in any manner.

[Karl Roth]

Very nice looking job, Thought about selling a kit?
karl

[Grizz]

Thanks, just used a hacksaw, drill, and a small welder to make the frames. All the steel and the plastic ends I picked up at my local Home Depot. I think there is a Smart dealer/store in Washington state that sells machined bolts for $32 each that go into the bumper.

[Grizz]

Here is the side view. It bolts into the bumper where the towing eyes go in. It looks like it's at an angle, but it is upright...my driveway is at an angle.

[geochemistry]

Your rack is much nicer looking than the bulky factory rack. Do you think the two tow eye bolts would be strong enough to hold a two bike rack?

[roverallover]

Very nice job Grizz
Have you tried putting a mountain bike on it? It looks a little close on that side shot and I think the handlebars may hit the back window ... what do you think?
Has anyone seen how that awful-looking factory rack mounts-up? I suspect it's to the same mounting points and therefore should hold up to two bikes.

Grizz ... you definitely should make more of those frames and sell them as a kit (let the buyer get their own rack ... less shipping involved).
Given what racks cost, you could do well.

roverallover

[Karl Roth]

The stock rack is designed to protect your gear and includes a bumper in the design. That said I prefer the clean look myself.
karl

[Grizz]

I built the rack to haul my bikes, I have hauled a 28 lb comfort bike and the thing held up nicely: it will probably support at least 50 lbs. It has the extra outrigger to support the heavy clamping arm on the Thule rack as it felt loose without it: now it feels solid. If you need more room for handlebars and such make the horizontal bars an inch or two longer. I let the top down on my cabrio until it barely clears the handlebars, then I cut the excess bars off. I made the "L" shaped drops to allow me access to the back after the bike is removed. Just thought I'd give you some options other that the base rack and bike mount stuff.

[El Tomate]

Originally Posted by roverallover

Grizz ... you definitely should make more of those frames and sell them as a kit (let the buyer get their own rack ... less shipping involved).
Given what racks cost, you could do well.

roverallover

I would be interested also. It looks awesome!
Fred

[Grizz]

Thanks guys, but I put in a lot of hours at work and when I'm not working, sleeping, or eating...I'm on my bike. Can't see myself trying to do mass production. I'll try to draw up some plans later this week and post them. All you need is to find someone with a small welder (I use one they sell at W*lm*rt for $99). Maybe a local machine shop can make the bolts for you (check out smartieparts)...enjoy