DIY hitch-mount swing out bike/tire/accessory carrier ...

Bret4207

At the casting bench in the sky. RIP Bret.
Thank you. I still consider myself an amateur at welding with much to learn. Every project gives me more practice time under the hood :cool:


I am Tig welding everything using my "old" circa-2003 HTP water-cooled Tig welder (which originally belonged to my machining & welding mentor). Not as modern and lacking options from the more recent HTP 221 model, but it still works well. This is my second HTP welder (my other one is the 2100 MIG welder) and I am super impressed with HTP:
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The small digital angle finder I got from Amazon a couple of years back when I was working on my custom 3HP 2x72 grinder & welding work table:
link to Amazon for Digital Angle Finder


My welding table is the Landmuir Arcflat - a solid cast iron size 24"x36":
link to arcflat machined welding/fixture table


I am welding this project with the "capacity" to support two loaded E-bikes, and potentially a tire/accessories as well. When I was doing the simulations for the steel bending under weight, I put the load at 500 pounds. But I don't have a way to properly simulate/design everything, so I am trying to make as strong/robust as I can.
Everything I've heard about HTP has been positive. Good for you! Thanks for the info!
 

wquiles

Well-Known Member
Got more "stuff" done. I fully welded the bike hitch mounting stub to the movable arm:
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Short video clip on the welding above:



Then started working on the lock & tensioner:
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After grinding away the finish:
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I also worked on adjusting the movable arm for proper alignment by drilling and tapping two new holes:
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Now in alignment:
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wquiles

Well-Known Member
OK, left those shiny parts in vinegar for a few days, so ready to weld more "stuff" today :)

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Welding the center ring to the arm/spacer (which is welded to the movable arm):
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Quick mock-up:
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Now aligning the other two which will be welded (also with spacers) to the fixed arm:
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Here getting the spacers welded to the upper and lower sleeves:
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wquiles

Well-Known Member
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Both done:
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Getting ready to weld the two sleeves. Note that I am allowing extra space for the arm to bend down under weight, and still clear the lower sleeve:
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Welding done:
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And here is the completed lock & safety pin "system":
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wquiles

Well-Known Member
On the moving arm (where the bike carrier is mounted), I am building a rectangular platform so that I can bolt "things" to it, including rotopax accessories, a possible tire plate attachment in the future. This is sorta of what I have in mind:
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Found the spacing for rotopax (2-1/4" ctc):
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This fixture welding table is awesome for this stuff:
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wquiles

Well-Known Member
These are the center pieces - strut material like I used in the roof rack:
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I still have to weld two short pieces horizontally between the two vertical strut pieces, but otherwise it is all tacked. These two photos should give an idea of how this new accessory platform would look like in the movable arm:
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wquiles

Well-Known Member
OK, change of plans on the top lock. Decided it would be on the way, so I removed it:photo00211.jpg
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Given the deep penetration of Tig, that left some ugly marks, so I filled them with Tig brazing rod (once painted, no way to tell!):
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Then started work on a "mechanism" to automatically hold the movable arm in place both when closed and when open:
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wquiles

Well-Known Member
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I then welded the "accessory" vertical platform to the movable arm:
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I welded this SS eyelet to prevent loosing the safely 5/8" pin:
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Get ready to sand/prime/paint:
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Then use the left-over Raptor bed-liner from when I did the roof rack:
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wquiles

Well-Known Member
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It was a little "light" in a few places (rant out of the Raptor stuff), so I used this to fill-in a little:
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Tap and install grease fitting:
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Packed and greased the bearings:
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More grease and then press the seals in place:
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I actually mounted the fixed arm in the hitch and assembled everything on the truck:
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wquiles

Well-Known Member
Assembled weight came to between 52-53 pounds:
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One of the "many" uses of the accessory mount is to carry these:
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I have the mounting plate for the spare tire, so that is one "accessory" I have to finish/weld/bolt on in the future:
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This is the completed arm in the open position:
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And in the closed position:
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Backup camera somewhat obstructed as expected:
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wquiles

Well-Known Member
Video clip: opening the swing out arm:


I got plenty good clearance when opening the rear hatch:


Another video - opening and closing (yes, the movable arm is tilted with the pre-load I gave it to compensate for the weight once bikes are added):


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I initially thought about doing this summer of 2021, so today is July 2022, and I am finally done!

Total cost was about $250 for parts, primer, paint, supplies, etc.. - still a lot less than the $1500 for the top-of-the-line model, and I would argue mine is probably strong enough.

I have a little to tweak, and touch-up paint in a few places, but I am pretty much done for now :)
 
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Bret4207

At the casting bench in the sky. RIP Bret.
Great job! And great photo essay. There's a guy I follow on YT from Estonia, goes under "Donn DIY". After seeing your stuff I think you'd like his stuff.
 

wquiles

Well-Known Member
Great job! And great photo essay. There's a guy I follow on YT from Estonia, goes under "Donn DIY". After seeing your stuff I think you'd like his stuff.
Thank you - it was another great learning project for me :)

I will take a look at Donn DIY - thanks for the reference.

Will