2008-12-2

          I made a custom detachable rear rack bike box system for my commuter bicycle. Using two rear wheel quick releases I can easily and quickly remove and reattach either of the two boxes. This is great for going shopping in which I can put the box in my shopping cart fill it then simply put the box back on my bike for my journey back home. No bags required.

          Here are three pictures of my bike with it's new bike box options. It rains all the time in the winter here in Portland, OR. Thus I used a heavy duty sterilite box with a lid that would keep my stuff dry as one of the box options.

Parts Needed 2 rear quick release skewers (I noticed that one of my skewers was a little longer then the other. The shorter one barely made it so try to get two longer variants. There probably are differences in road vs mtn wheels and the age of the wheel that the skewer came off of) 2 1 inch diameter pipes 5 & 3/4 inches long 4 washers that can be welded to the ends of the pipes and allow the skewers to stay centered in the pipes 2 boxes or crates of your choice 1 4 foot piece of 3/4 inch aluminum slat 1 4 foot piece of 1.5 X 1.5 inch aluminum angle iron 1 can of rustoleum to paint metal pieces for rust prevention Hardware to attach quick release tubes to bike rack Hardware to attach aluminum mounting brackets to boxes Tools recommended Safety glasses and ear muffs Right angle grinder Welder of some sort. I used an oxy acetylene set up with filler rod for added metal. Basic wrenches for hardware attachment Drill with drill bits sized for hardware bolts to fit through Vise

           I suspect many people do not have the ability to weld. You could take your pipes and washers to a welding shop and it would be an easy job for them to do it for you. You might also be able to find some kind of a metal cap to put over the ends in which you could drill holes for the skewers. I am unsure as to what would fit though. A copper plumbing cap might work well if it can be fitted over the steel pipe. Copper pipe should not be used as it would be too weak and would buckle over time from the pressure.

          You need something that is going to be stiff enough to allow the skewers to squeeze against when pinching down on your box attachment points. Without a firm backing (Provided by the pipes) the skewers would just deform the plastic box or crate that the box attachment brackets are bolted to. 1st I welded the washers onto the ends of the 5.75" long steel pipes. I then found convenient attachment points to mount them under my rear bike rack. My particular rack had an aluminum plate that was strong enough to drill and slide bolts through with washers. I am sure there are countless ways to attach your skewer pipes to your rack.

           Next you need to make the box attachment brackets. Cut 2 pieces of the aluminum 1.5" X 1.5" angle iron to a length that is sufficient for what ever box you are attaching. I then held each piece up to their corresponding side of the skewers and marked where to cut grooves. I didn't have a nice way to cut the aluminum so I just carefully did it by hand with the angle grinder. Be careful to not cut the grooves to deep as the QR attachment pieces are located below the top of your rack. Keep this in mind and measure and mark several times before cutting. Grind as necessary so they don't hit pieces of rack and slide right onto the skewers. Next with the aluminum angle pieces tightened down into the quick releases on the rack, place the box on and mark where your bolt holes are going to go. Mark and drill bolt holes through the angle iron, aluminum top plate, and into your box. Be careful when drilling your box, the plastic likes to crack if you catch an edge.