As always,it's a case of, 'if I can do it, you can too '. I built this box on a portable bench on my back veranda.Just basic tools required; you shouldn't need to invest in any special or expensive equipment.The box is designed for a bike with a straight handle bar and a fairly long stem.Nitto 'Left Bank'is perfect or perhaps even a Bullhorn style bar.I used light weight,external ply,8mm thick and then beefed it up with some aluminium angle.In retrospect,a slightly thicker ply, without the angle would probably have worked just as well.
Confession:My father was a self taught carpenter who had the ability to hand saw timber straight and square, by eye. I do not have this talent, hence, I had my local timber merchant do the hard yakka. It costs a little extra, but it's well worth the cost, as everything will be square and true and to the nearest mm.(Attention Australian readers, don't entrust this task to Bunningtons.Much better to find a local timber yard.) For the aluminium fittings, I used an old 'mitre box'.(I think that's what you call it)to achieve squareness.Don't worry if you don't have one as no one but you will notice if it's a little out of square.
Materials 1 x small sheet external ply wood,approx 8mm thick
1 length aluminium flat bar~25mm x 3.0mm x 1M
1 length aluminium angle~20mm x 20mm x 1.5mm x 1M
stainless steel nuts and bolts
external varnish/ weather proof oil
2 pce old inner tube
Araldite 2 pack cement
Tools Electric drill plus bits
files flat plus round
sand paper~various grades
50 cents per cut~I'm a slacker,I know it, but this saves a lot of stress.(and cursing)Thanks Peter!
Selley's weather proof Aquadhere is the glue that holds the whole thing together.15mm brads used to apply the pressure until the glue sets,say 1 every 50mm. I pre drilled both pieces of timber to prevent the nails coming out where-ever.This wouldn't be a problem with a slightly thicker ply.
Cutting the 'stem bracket', using a mitre box,if you have one. This is bolted to the underside of the box and holds it up against the stem to prevent it from sagging.Note the WD40. Home handy person's best friend.
Cutting a curve in the 'stem bracket'with radius equal to that of the stem. I roughed it out with a pencil and then drilled holes around the curve. Made the final cut by hand and finished off with a half round file.Aluminium is easy to work with but just as easily damaged.If it gets scratched you can simply sand it smooth again.
Bending the handle bar hooks to suit the handle bar diameter.(there must be a more professional way to do this!?)
Underside showing the stem bracket.Note drain holes in the corners.