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Cal Poly Bike Builders Learning Project
Cal Poly Bike Builders Learning Project
As a way to improve the training of bike builders members, I developed a rack building project. The project needed to develop the skill set to build a bike: mitering, fitting, welding, and brazing. It also needed to be useful and affordable for a new member to do.
The project was also made to be as customizable, with multiple versions and add-ons to make the project as broadly appealing as possible.
This project has successfully been run for two years of new bike builders, allowing for the project to be streamlined and run as efficiently as possible to get members building.
Fixturing
Fixturing
Adjustable fixtures designed to be used with multiple different rack designs and dropout widths. Using 3D prints and threaded inserts, they have been made to be repeatable and easy to replace.
Documentation
Documentation
Everything from process to materials is documented. Scale drawings for routinely inspecting parts were made. A handbook covering styles, processes, and modifications was made.
Customization
Customization
The geometry was chosen for modification. Many different versions off of the base model can be made including racks tailored to bikepacking and cargo hauling.
Many Builders
Many Builders
Many new members build the rack to get experience. With so many people all building it, it has meant expanding tooling, storage, and teaching.
Showcase - MADE 2025
Showcase - MADE 2025
Member builds were showcased at MADE 2025. As a student organization at the event, showcasing how we train new members is an important part of how we represent our club. Additionally, it adds a way to recognize the hard work of new members. Some of this recognition came through a sponsorship I arranged with Ortlieb for free bags for each build.
Stainless Steel Rack
Stainless Steel Rack
This rack was designed to be ideal for commuting. Features include a low rider pannier level, stainless steel construction, taillight mount, and slim geometry. The low rider pannier level allows for weight to be kept lower and improves handling. The stainless steel construction makes the rack extremely weather resistant and able to be left as a raw surface. The tail light mount provides holes to bolt a light onto the rack itself. Finally, multiple bends were used on each vertical tube of the rack to taper the geometry.
3D modelling of rack
3D modelling of rack
The rack went through many revisions with changes being made to simplify manufacturing and to account for tube elongation during bending.
Fixturing
Fixturing
3D printed fixturing for verification and tube location during welding
Bending
Bending
A maximum of three bends were used on a single tube meaning part clocking and consistency were vital to making a symmetric rack.
Pizza Rack
Pizza Rack
Using the standard rack project design I modified it to have a larger platform. This platform provides convenient storage space for larger items or storage bins. Additional bottle bosses were added to the top platform to allow bins to be bolted onto the top of the rack.
Bikepack Rack
Bikepack Rack
A variant of the standard club rack design with an angled top. The goal with this design was to maximize the space for a drybag on top of the rack. With limited space between the wheel and a dropped seat. The flexibility of the fixtures allowed me to draw this design out with carboard and manufacture within a weekend.
Titanium Bikepack Rack
Titanium Bikepack Rack
As a collaborative project I built a titanium rack with my friend. Since he was building a set of titanium bikes the racks offered him a chance to practice welding and I got the chance to bend, miter, and design a new rack. This rack was designed to minimize the number of tubes while still maintaining the form factor of a traditional pannier rack. This meant the many more bends had to be made, giving it a much more flowing form. The final design featured a single part with 3 pairs of bends that had to be symmetric and in plane.
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