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

[wquiles]

I been wanting to make something like this:


or this one:


But I also wanted to make something stronger enough that could be used to carry a heavy spare tire as well, like this one:




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The rest of the thread has the work-in-progress photos, but here is one photo of the finished project (late June 2022):






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So I spent months looking at videos, photos of about 10 different options, including some DIY designs, trying to come up with a version that had the features I wanted for my Toyota 4Runner. I actually started thinking about this project in late Summer, early fall of 2021, so it has been almost a year since I had the original idea for this project.


For the moving arm, even though my implementation is a little different, I went with the excellent design from Taboo Customs:
Hub and Spindle Kit-Side Mount-Double Shear P0498





I started cutting metal around Jan-Feb of 2022 - this is a factory Curt 12" piece:



After I measured using my 4Runner as the target, I used an on-line calculator to compare the flex of various cross sections/shapes/wall thickness for the fixed and moving arm:
Hollow Rectangular Beam Deflection Calculator


I settled on 4"x2" by 1/8" wall tube:



Mockup:






For the portion that will go into the 4Runner hitch, I wanted it short and slanted to make the exit angle as high as I can reasonably make it:

 

[wquiles]

Like most of the better/premium solutions, I am creating a built-in anti-rattle mechanism:



I used a 6mm bolt to force the 45deg piece into the main body to take slack away:



I took the nut off before welding of course - just wanted to have the right spacing:






This is the other side of the wedge:



Left open in the bottom to allow water to flow out:



This is the assembled body and wedge:



You can see here the lock nut:

 

[wquiles]

To increase the strength of the body, I welded the end completely:



I then welded the body to the new hitch piece. Tack, root pass, and two more passes for strength:










I then welded the first pieces of the kit from Taboo. I did make a mistake, and did not allow the 0.120" excess at each side - so I had to adjust the barrel so that I had the extra distances:

 

[wquiles]

Then weld on the other side:





Then started welding the other kit pieces:









Mockup:

 

[wquiles]

Work on lathe to deepen the bored surfaces to fix my error. Again "my" error - their documentation showed this, but I missed it:



Now everything fits great:








Used barrel to mark the tubing to fit:

 

[wquiles]

Reasonably good fit for my skill level:





Label everything before welding:

 

[wquiles]

Due to the slight warping after welding, I had to lightly grind the soft mild steel barrel to allow for the hardened race to fit in place:



I want all pieces to be sealed - no place for water to get inside:

 

[wquiles]

Allow for bending under weight, I inclined the moving arm to be "about" 1/4" higher than the fix arm:













Since this part from Taboo is meant to be welded on a larger/flat surface, and since I had over-hang on the bottom side, I welded two re-enforcements:





Of course this affected the alignment, so I had to clamp and use my torch to "adjust it back:

 

[wquiles]

For the fixed arm which is welded to the hitch insert, I also re-enforced that area:



Like always, tack, root weld, and then additional passes:


But I did a quick "check" on the 4Runner:








Now fully welded, with the hitch pin in place, and the anti-rattle wedge on tight - fairly nice alignment with the bumper - not bad for an amateur:

 

[KeithB]

Wow. Just wow.

 

[wquiles]

The bumper is curved, but I have at least 1" or so of clearance:



and of course the pivot point is past the rear hatch:



This is the small space at the back at the hitch, where the 6mm wrench can make the wedge tight:



Now ready to cut the new hitch which will hold the bike carrier on the movable ark:



Then need to cut the moving arm for a nice fit:



Partially cut in the bandsaw:

 

[wquiles]

Now start the tough part:






Then cut:



Clean/trim:

 

[wquiles]

Since the bike carrier will torque down the arm, I adjusted it a little "up" close to 2 degrees:









Get ready to tack:





and I ran out of gas - or almost. Don't want to risk running out of gas, so I stopped for the day:



Next time I get to work on the lock and safely pin. Here is where I will likely weld the lock:



Another mockup, this time I can check the full swing while mounted in the 4Runner - top plate is not fully bolted yet - held in place with a wrench for the photo:





I have more to go, but wanted to share what I have done so far (Sunday May 15 2022).

 

[CWLONGSHOT]

Nice work!!!!

I have made two of these myself! One on my '99 TJ and a second on my '89 MJ (Comanche pick up)



(I also made that trailer. Completely)
CW

 

[Bret4207]

OUTSTANDING photo essay!!!!! Well done man! You should be proud of how nicely that's turning out. Love the welding table, really need to come up with something in that line myself...and a TIG set up. What kind of TIG are you using if I might ask? Also, what is the make/model of the degree finder/inclinometer doohicky? Looks awfully handy!

Is this for a bike, as in bicycle or for a small motorcycle?

 

[Bret4207]

Nice work!!!!

I have made two of these myself! One on my '99 TJ and a second on my '89 MJ (Comanche pick up)

View attachment 27461

(I also made that trailer. Completely)
CW

Nice trailer! Resembles the military oversized "1/4 ton" trailers we see up here near Ft Drum.

 

[wquiles]

Nice work!!!!

I have made two of these myself! One on my '99 TJ and a second on my '89 MJ (Comanche pick up)

(I also made that trailer. Completely)
CW

Thanks. Work in progress, but going well so far.

After reading a couple of threads on poor welding for "premium" trailers, I am convinced I will make my own small/utility/camping trailer as well. Another "future" project

 

[wquiles]

OUTSTANDING photo essay!!!!! Well done man! You should be proud of how nicely that's turning out. Love the welding table, really need to come up with something in that line myself...and a TIG set up. What kind of TIG are you using if I might ask? Also, what is the make/model of the degree finder/inclinometer doohicky? Looks awfully handy!

Is this for a bike, as in bicycle or for a small motorcycle?

Thank you. I still consider myself an amateur at welding with much to learn. Every project gives me more practice time under the hood


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:



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.

 

[CWLONGSHOT]

Nice trailer! Resembles the military oversized "1/4 ton" trailers we see up here near Ft Drum.

THANK YOU, That was my vision. Great trailer that pic is almost twenty years old! Its going strong today! Many dump and vacations. Its been from Alabama to No Maine.

 

[Missionary]

Thank you for all the fine photos and write-up! I do enjoy reading these.