When making your own bike rack, you have a number of options for the materials and style. You can make an upright wheel rack for one or more bikes using PVC pipe, steel pipe or welded rod. If you have woodworking tools, you can design and build a hardwood rack. In the event you need a roof rack or bumper rack, it's best to consider a manufactured unit designed for transporting bikes. One of the easiest racks to make consists of a wood base and wheel guides with plywood partitions. The rack is sealed to resist moisture. You can make a sturdy bike rack using everyday carpentry tools.
Base
Step 1
Establish the width of a base for the rack according to the number of bikes the rack might accommodate. The wheel guides will be 3 inches wide and spaced 12 inches from each other. The guides at each end of the base are inset 3 inches. A rack for three bikes, for instance, would be 45 inches wide plus 6 inches for the insets at each end.
Step 2
Cut 2-inch-by-4-inch front and back rails of the frame to length using a circular saw. Cut two 30-inch long 2-inch-by-4-inch end rails for the base.
Step 3
Position the base rails on edge and align the corners. Assemble the base using a framing hammer to drive two 16-penny nails at each corner. The nails should be 3/4-inch from the end of a piece to prevent splitting the lumber.
Step 4
Lay the base on a flat surface. Mark the front and back rails at the locations of the wheel guides and include the 3-inch insets at each end. Cut pairs of 2-inch-by-4-inch wheel guides that fit between the front and back rails.
Step 5
Position the wheel guides on edge in the base frame and align your 3-inch marks. Attach the guides using two 16-penny nails that you drive through the frame from the outside and into the ends of each guide. Set the base aside for now.
Partitions and Assembly
Step 1
Lay out right-triangle partitions for each wheel rack on a sheet of 3/4-inch exterior grade plywood. The base of each triangle is equal to the length of the wheel guides. The height of each is 24 inches from the bottom of the base. The long side of the triangle slopes down toward the front of the rack. Mark the lines for each cut using a chalk line.
Step 2
Put on your safety glasses. Cut the triangle partitions with the circular saw.
Step 3
Set up a cordless or electric drill with a screw tip attachment. Stand a partition in the frame against the outside edge of the first wheel guide. Attach the partition to the guide using 1 1/2-inch galvanized wood screws spaced 4 inches apart. Attach the remaining partitions the same way, making sure each is on the same side of a wheel guide as the first for a uniform appearance.
Step 4
Cut a piece of plywood 12 inches wide as a brace for the partitions. The length of the brace equals the distance between the outermost edges of the end partitions. Attach the brace flat against the back of each partition with three galvanized screws at each connection.
Step 5
Seal the entire bike rack with all-weather sealer that you apply in generous amounts with a utility brush. Allow the sealer to dry and apply a second coat.
Tips and Warnings
- Use 2-inch thick lumber spanned across sawhorses as a worktable when cutting plywood. Trim the edges of the partitions with aluminum channel that you cut with a hacksaw and attach with construction adhesive. Cut pyramid plywood partitions and make a double-sided rack.
- Do not use MDF or particle board as partitions on outdoor bike racks. These materials do not withstand the stresses of the elements.
Things You'll Need
- Safety glasses
- 2-inch-by4-inch lumber
- 3/4-inch exterior grade plywood
- Circular saw
- Framing hammer
- 16-penny galvanized box nails
- Chalk line
- Cordless or electric drill
- Screw tip attachment
- 1 1/2-inch galvanized wood screws
- All-weather sealer
- Utility brush
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