DIY Cargo Bike - Turning an old mountain bike into a cargo hauler

DIY project documenting the transformation of a Gary Fisher 26" steel mountain bike into a cargo bike similar to a Surly Big Dummy, Xtracycle, or Yuba. The original frame was extended using parts from two donor frames and some thin-walled steel tubing. The bike is finished with custom wooden fenders, running boards, and cargo deck.
The bike isn't light, but not as heavy as you would expect. It is about 15 lbs more than the original mountain bike with all the added parts. It's a little slower to get up to speed than my commuter bike, but cruises along nicely. The 3x7 (21 speed) drivetrain is very durable and has plenty of range.
The overall project cost was about $180. It was a fun project with a great result.
One important detail: the name of the bike is Blue Steel. :)

[@fraaggl]

1:20 small tip : you can attach a small string of wire slightly tighten at the extremities to determine by sight the alignements. The wire goes from the end of the rear fork to the pedal axis for example and the same on the opposite side in simetry, so you can see the angle made by the wire and compare them. I use this simple technique all the time it's very efficient.

[@NotLeftarded1]

Love this , my favorite color too . I'm a true blue Canadian.

[@johanstrom3271]

I appreciate that you DON'T have music, when showing your creativity!

[@unbearable9770]

Awesome video! A special thank you for NOT playing crappy techno music in the background. GoPro on the table saw was a nice touch. Now I do have to ask about a kickstand. I didn't see one and I really want a kick stand on my bike.

[@MtbEngr]

It's funny how many people like the lack of music! I still haven't built a kickstand, but I should. Thanks!

[@MoPoppins]

Great build, excellent job documenting and EDITING it all. Thanks to your sensibilities for flow, the pacing was perfect...video was only as long as it needed to be. I want to learn to weld, and when I do, a custom bike build's gonna be on my project bucket list! Thanks for a fun and inspiring video. :)

[@TekkamanBiker]

Nice project. People say there is no music in the video, but you can hear Rammstein in the end.

[@harveyboy45]

Awesome build. Simple straight forward. I'd like to see more details of your welding and alignment.

[@eternaloptimist2840]

You can make a really simple jig to hold the bottom bracket and rear axle parallel and at the correct height; everything else can be done by eye, with the assistance of a spirit level, a straight edge and a bit of string.

[@leqin]

Gary Fisher would be proud of you. There is nothing Gary likes more than someone making a bike useful. Anybody saying anythingelse is as unknowing as all those idiots who say you shouldn't put Campagnolo on Specialized... guess what brand bikes they use in the Campagnolo research center :.) just across the road from the main factory. Well done and really useful video.

[@MtbEngr]

Thank you. There's quite a few different sources of steel in the bike including an old road bike and part of a headboard (really thin salvaged tubing). It was all pretty much the same alloy. It's always good to put old junk to good use.

[@iainjones2881]

I really like it, I've been wanting to build one for a while but with the addition of an electric motor. you've given me the inspiration to build it many thanks.

[@oscarpaisi4037]

i get the same idea my friend. Ebike mtb deliver/ cargo is the future.

[@mrgcav]

Great job, The running boards are wild.

[@alistersibley2155]

Cracking job!!! Brilliant bike and a great film!!!

[@samuelneil7490]

Pro trick : you can watch movies at Flixzone. Me and my gf have been using it for watching loads of movies during the lockdown.

[@sylashouston5093]

@Samuel Neil definitely, been watching on Flixzone for since november myself :D

[@DivineMisterAdVentures]

Your "documentary" is really a treasure!

[@andressalas4266]

Dang! I wish I knew how to weld. Only a woodworker, for now.😉. Awesome job man!!👍🏽👊🏽

[@dickflinghammer7643]

Same here but I welded in high school. I build awasome stuff no excuse not to by a welder for me anymore

[@eternaloptimist2840]

You could probably make the whole back end out of plywood with a few steel plates for mounting, and bolt it to an unmodified frame.

[@thornwarbler]

Grand job, mate.

[@Bikemaddad]

That is next level man. Legendary

[@elijahf111]

dont know what u think a mountain bike is but that looks sick!, guud jub

[@arad4912]

Fantastic, it took some skills and tools and place to work,it seems like much, much more than only $180 but still very good job.

[@dragster9886]

awesome build love the paintjob

[@guspompa3283]

Excellent I have this new idea good job keep making more projects

[@dconsiuc]

Looks great! I have no idea what is going on and I feel totally incompetent, but it looks like such a great idea! Where does one even learn these skills?

[@sanyaveloshahta]

Sir what is the weight of your truck?

[@Aaron-mx3bh]

Great video! thanks for the outtakes too...made me laugh!

[@thepianotromboneguy]

to be honest the pricing would have been a bit off - the tools used to weld, cut, etc. were not taken into account when stating the final cost. Otherwise this is great, an excellent way to make something useful out of cheap, regular things!

[@e-bikecommuter6336]

Well done! Great build!

Nice stuff

[@kgeorgejunior]

Beautifully made!

[@zackerylunde]

Looks great! Turned out awesome

[@thomassteenerson7226]

Do you build them if so what would you charge for labor on top of the price

[@scottthomas7571]

I love the fact that I now know I can weld up a bike with my everlast welder. Cargo bike here I come!

[@selivokhin]

Great project! thanks for inspiration!

[@paul1153]

Cool build.

[@carljansevanrensburg2440]

Nice build

[@alexismalafosse6784]

Very good job !!! Very cheap !! Very nice !!!

[@markifi]

so nice!

[@karolthiesen4707]

I really want to make a longtail bike with my everlast welder. A longtail would be so useful for me.

[@1MasterLi]

Awesome proyect

[@justinbarney6286]

What I've never been able to understand, is why so many people paint their bikes a dark color ...black, blue, etc. Personally? --a seen cyclist, is an alive cyclist, so it's with that in-mind I'd go with(excuse my spelling) fluoresent colors and/or(3M) reflective paint.

[@bikefzx2132]

Nice project. I tried to make a cargo bike years ago but just didn't finish it. Brazing took too long and I simple gave up. (Project videos on my channel) I made a tandem too and am now thinking of converting a tandem I made to a cargo bike like yours - Thanks for the ideas.

[@MtbEngr]

My original plan was simply to buy an old Schwinn tandem and make it convertible between tandem and a cargo bike. Simple and cheap, and those old tandems are classics.

[@bikefzx2132]

I had the chance to ride a tandem with a girlfriend 25 years ago and jumped at it. Shouldn't have because we just didn't go anywhere with that noodley frame at fat tires. But it would be perfect as a cargo bike and convertible is always good.

[@unbearable9770]

Hey, I really want to see a tandem cargo build. Somebody do that.

[@surferboycoolable]

How does this dude have such a tidy workshop!

[@mrjodoe]

steel frame 25CrMo4? Do you have at least ER70 or higher filler Material?

[@joopmoto9416]

Great Project

[@kirtottosen5924]

Nice job.

[@oldbaldfatman2766]

May 31, 2018---Outstanding job, but how does it perform on a dirt trail?

[@johnfitbyfaithnet]

Nice job

[@command0z]

Roughly how wide across (and long) did you make your cargo rack?

[@martinzgz23]

Great work!

[@unbearable9770]

I've watched this a few times. The running boards are removable, correct? It looks like they are mounted on tubes that then slide into the main frame of the cargo rack.

[@MtbEngr]

Yes, the intent was to make them fairly easy to remove and to be able to add different attachments in those tubes such as a sidecar or mounts for hauling different things. I've only used it with the running boards so far.

[@chewa1983]

Rammstein in the end ;-)

[@command0z]

Great video! When you notched the seat stays to bend them to the correct angle, did the back brakes still align properly?

[@MtbEngr]

Thanks! Yep, all close enough. Needed to make some final adjustments to the brake pads like any bike, but there's plenty of adjustment range in those pad connections.

[@command0z]

@@MtbEngr Thanks! This video is hugely helpful. We really appreciate you putting it together!

[@wesslee9060]

Why didn't you use the bike with the suspension fork!!!!!!

[@RKogi]

Well done man !

[@raijin7707]

interested in making me one that supports 26 in wheels? What sounds like a fair price?

[@Akkendran]

Really nice project, just one question: How did you bend the wood and made it stay in shape for the fenders?

[@MtbEngr]

I steamed the wood and bent it around a form. Once the wood dried, it maintained its shape. Making the mounts for the fenders was much more of a challenge, but I ended up using zip ties to the frame and welding custom metal U frames to support the back of the fender.

[@fudk_off1312]

why not start with a tandem bicycle frame?

[@Jazzmarcel]

Excellent!.........

[@josesoto9099]

You probably get a good workout hauling with that water jug full

[@zoltizolti3165]

welding machine tipe?

[@josephdupont]

I would make a camper bike.. not a trailer.. you can use that corofoam for the sides to save weight.

[@leftcoastminis]

this is rad, how much does it weigh?

[@LatinDanceVideos]

What size tubing are you using?

[@nathanmichels1252]

Great Build, What kind of welding did you use?

[@ameraldas3641]

sounds like mig to me could be flux core

[@conerblaine7876]

I also have a question about the initial extension piece that you welded to the bottom bracket/chainstay area. Did you add/weld a square piece to that extension piece for better contact points to weld and then grind them down to shape?

[@MtbEngr]

Yes

[@ramingo.craftsman]

beautiful!!

[@janbolek762]

Good idea. One question about weigh ? kg ?

[@Pushyhog]

Do it in fat tire now. And put a bafang on it.

[@panamacz98]

did you use mig welder or flux core?

[@MtbEngr]

I currently use a Hobart Handler 125 set up for flux core. Flux core works well for infrequent usage and it makes very nice welds with the right technique. It's a great little welder.

[@adijayaification]

Inspiring

[@MH-cj1gz]

what type of paint did I you use and the color of blue is it? Awesome build

[@myvicariouslife4012]

Very interesting...but can u manual with it?

[@fudk_off1312]

why didn't you just use a tandem bike?

[@apmdri]

Mande um Brazil! Urgente! Eu preciso!

[@fudk_off1312]

in a world where the tandem bicycle was never invented

[@cup_and_cone]

That rear luggage rack is way overbuilt. I think the rear wheel*s* will go long before the frame!

[@joelongstaff7601]

Well done mate.Take someone else s hand off and make them useful again. I went to the dump and draged home three old bikes.Hopefully To replicate,ha ha, what you've done.Next a trailer.

[@firstalexey]

HOW MANY WEIGHT BIKE?

[@conerblaine7876]

Did you leave the seat stays notched with that extended piece welded at the seat post adding the structural support? Great job by the way!

[@MtbEngr]

Thanks! I welded the notch closed once everything was aligned.

[@schutztruppe]

10 thumbs down??????????????? haters !!

[@neta1538]

well done!! is it still running and in frequent use?

[@RobBastien]

Great job. How is it holding up?

[@iWonderOfficial]

Now put cushions on the back and have a tea party while riding

[@christianalfonsoreysokolov2739]

bery cool man, i was dreaming for a bike like that, but how many kilos it weights?

[@MtbEngr]

Not too sure, probably 45 lbs or so with the fenders and wood rack: ~20 kg. It cruises nicely.

[@greggsaunders3246]

Very cool. Do you have anymore detail on the fenders? That could be a cool project for my around town bike.

[@MtbEngr]

I may have to do a video on making fenders sometime. Next time I need another set...

[@alessiozago]

Grandioso!

[@jamesellis5549]

next time paint a straight line on your work table,that way you can align all the frame components in reference to it and screw or clamp parts down before welding

[@ameraldas3641]

or use a chalk line

[@myjuancarlosavellanedadiaz9984]

Noooo Gary fisher bike ruined!!! But I can't see all video

[@grindz145]

sweet!

[@MtbEngr]

Who thinks I should upgrade this to an ebike using random old electrical parts?

[@Leavemykindalone1154]

Thicker the better Sell them locally $1000 Make sure it can hold 440lbs Long periods of time weeks of of heavy weight

[@pefp2008]

The build is cool and all, but what happens when you don't have the tools?

[@firstnamesecondname3647]

Rammstein ✊

[@gabrielgomescunha]

Overcomplicated but good work anyway

[@otheremail123]

You could sell those.

[@ericmiranda9841]

Nice 70 pounds bicycle......

[@apmdri]

🇧🇷?

[@mrMacGoover]

It's ugly but it works!

[@Metal-Possum]

Did you just hack up a Gary Fisher and attach parts of a Diamond Back to it? You're not supposed to mix different quality brands like that, Gary Fisher himself ought to slap you for that.

[@quoththeraven3985]

180$ plus labor = 1800$..lol

[@bicycleandrccars568]

shit no sounds. not good

[@61tree_VR_Gliding]

Awesome job!