How to Build a DIY Cargo Bike (Plans available!)

Ever since I built my first cargo bike and uploaded some pictures of that build to reddit, I've been getting many questions about the bike, how to make it and on cargo bikes in general. Since so many people seem to be interested in building this kind of bike, I've finally decided to put out a proper tutorial on how to build one. Even with a long video like this, it's impossible to include all the necessary information like measurements, so I also made a set of plans to cover all the numbers and theoretical stuff.
So this is a deviation from the video format I used to do so far and I'm interested to hear how the audience likes it. I'm considering making more videos like this that focus on teaching/explaining things more.
🔧 LINK LIST for tools I use in my videos:
hero.page/philvandelay/my-fav...
📐 PLANS: www.etsy.com/listing/746194519/
👕 SHIRTS / Merch Store: phil-vandelay.creator-spring....
🙏🏻 Patreon: / philvandelay
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TIMESTAMPS
0:00 Opening
0:46 Introduction/Backstory
1:46 Bike Overview
2:32 Materials Overview
4:37 Frame Jig
6:26 Cutting Donor Frame
7:30 Building new Downtube
14:45 Adding Gussets
16:03 Building Cargo Bay
18:44 Building Steering Shaft
21:33 Building Steering Linkage
27:42 Building Kickstand
30:57 Frame finishing touches
32:50 Painting
33:57 Making Cargo Bay Cover
34:51 Final Assembly
37:12 Final Words/Ending Montage
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Additional Links:
📐Adding disc-brake tabs to a bike frame without using a jig: • Compact Cargo Bike / C...
📷 The photo story for my first cargo bike: imgur.com/gallery/DAijq
#lastenrad #cargobike

[@porkchop955]

Absolutely positively killer design and craftsmanship. As someone who runs 90% of his errands on a bicycle, a cargo bike of this design is on my wish list.

[@FunkyBuddha81]

and did you build it allready ?

[@porkchop955]

@@FunkyBuddha81 unfortunately not. I still make do with a 1994 C'dale MTB with racks front and rear.

[@TK-OK]

“The most important thing you need is motivation and you can’t buy that” bravo 👏 well said sir

[@ConiferProject]

Yes, you need videos like that for motivation :) 👍

[@marianohernandez198]

@@ConiferProject 👍

[@britzwickit]

haha, came here to post this, followed by a "PREACH!"

[@deusvult125]

subed for that

[@DonnyDarko13]

and a workshop+ enough space and money for materials and tools +machines ;)

[@israelcantuta541]

“The most important thing you need is motivation and you can’t buy that” I just love this phrase because it's so true :). Great job and I've started to visualize building one by myself.

[@oithetresen609]

me too. But I first need to save some money on an AC TIG welder because I want to do this whole bike out of aluminium. Mainly because I have tons of it lying around and I barely own any steel.

[@BighypeBeats]

5 years ago he made a bike with no experience 5 years later this guy makes tecnical drawings and 3d models Great development

[@alecto1550]

Well 5yr is not short..

[@lilsazon]

@@alecto1550 yes it is

[@s.sradon9782]

@@lilsazon I 3d printed a 300w portable sun within 1 week with no previous experience of anything engineering. It worked 1st try and while smaller than I bicycle and mechanically simpler it's more complex. 5 years is not that short

[@TheMe2oo]

Can you tell me which software he used to draw these project? Thank you

[@s.sradon9782]

@@TheMe2oo just use fusion since it's free

[@AlexandreVerney]

Thanks for the video ! I actually drew a LOT of inspiration from your first cargo bike tutorial and we made our own with my wife and father last year. With this video, everything is a lot more easy to understand and I hope people will dare to build their own. Thanks again !

[@PhilVandelay]

Thanks! I was surprised how many people were inspired by that and went through the effort of extracting the information from those pictures. I hadn't intended the post as a tutorial back then since I didn't expect people would like it so much they want to recreate it. And I also never wrote down any measurements back then.. so that's why I had planned to do this video for a long time, we need more cargo bikes in the world :)

[@womacko]

That joke with the sponsors, got me 😂 3:38

[@bob-ny6kn]

... and "... sorry USA :(..." hahahha.

[@wrjensen2353]

I got a good laugh too.

[@user-sw2er4bv1r]

why i subbed lmao

[@Mtematiks]

Me as well, I was on the edge to close the video :)

[@dfhhjle8866]

hahahaha i knowwww huh...

[@grandpasbarn2806]

The tip on citric acid to remove plating is great, used it last weekend on some 3/16"' diameter rod. What a lifesaver, thanks. Even though ill never build a cargo bike, I enjoyed the video and always enjoy your craftsmanship and peaceful demeanor.

[@JaySims]

Looks like this was actually built out of necessity- not just a build for likes- Very impressive and inspirational- been wanting to do something like this for some time.

[@AdrianTache]

Me before watching the video: A 40-minute bike build? I don't think this is worth watching. Me after watching the video: That was awesome!

[@mikehunt-zx8tr]

"The most important thing you need to build stuff is motivation and you can't buy that" I love that

[@MarinusMakesStuff]

What a nice project log! Thanks a lot Phil. I just started working at my old art academy and there they have all the tools to build a project like this. Wood workshop, metal workshop, CNC mill to mill wooden parts.. I can just mill out jigs to hold the metal parts in place. Then move everything over to the metal workshop and simply assemble the bike there using all of the jigs. I might consider this project as it's really something that challenges me and I like a challenge :) Thanks for the inspiration! I know it's very hard work to besides doing such a project, also document every step in a sensible way.

[@iainmel1]

Firstly, informative, concise and INTERESTING enough to watch to the end, and come out of it inspired and itching to get going! Secondly, how refreshing with the calm voice and calm musicwhich actually seems to disappear. Logical sequence, a little humour and fun to watch thanks!

[@JoelRavier]

This is incredible. I've been wanting to build this type of cargo bike for a few years now. Excited to buy your plans and no longer have any excuses not to start! Thank you!

[@thomashughes_teh]

When I was young my grandmother instructed me to "Learn something new every day of your life". I think I'm averaging good to the end of the month after this video even if I learn no more.

[@undernoillusions1448]

I really appreciate your no nonsense approach ( w/o streching the timeline b.s.that so many videos favor) . Not that I'm saying everything need be uber serious though. .Your delivery and" cut to the chase" detail overview, with the admix of alternate possibilities ( pro and con ) made me an instant subscriber, follower, fan i.e.fanatic😁 (which means I will be pointing others to your channel and existence) and as a person who will only give real - or none at all - compliments ...I say " this was a joy to watch from start to finish." Thank you !

[@PhilVandelay]

Thanks! My vids have a tendency to get too long as it is, so I try to keep it as concise as I can without skipping major info. Glad to hear when people notice it!

[@GraemeRobinson]

Thanks so much for posting this video - inspiring stuff! Some great tips there for the first timer and I like that you encourage anyone, no matter what their resources are, to give it a go.

[@DolfocarAli]

Most of my project I take from KZbin and this is by fare the most intriguing one I watched in months thanks for sharing 👍🏻

[@Dvirshe]

What a huge effort, both in planning and execution and in photography and editing. You through a lot of good advices all over the video, this advices are really helpful. Thanks a lot.

[@newsonair]

Your narration was so impressive, just like the way you made the bike... Clear and understandable to even a layman. Tnx for uploading this n wishing you all the best with lots of love... Enjoy the ride...

[@thomasgaumont3256]

Great work ! great plans, thank you so much for it ! I did mine for about 410€, 100 hours. I was a complete beginner in MMA welding. I spent a long time doing the welding. I had some difficulties for finding the 1”1/8 steal fork before I realized it was BMX standard. Another problem I had : I didn't manage to extract the bottom bracket, which was very seized up. I was affraid welding without removing it would burn the grease or even weld the ball bearings. Hopefully it is still rolling and no particular problem until now. And I did a small mistake with the steering tubes dimension (too thin) so I've been tinkering to make it fit. My advice : choose a good donor bike, I lose money buying new gearing, and other new bike parts.

[@PhilVandelay]

Nice! Also good to hear some feedback on cost and build time, 400 bucks and 100 hours is about what I would guess as well for an average build. Looks like you also learned a lot of new stuff which I think is a big pro with taking on a project like this. Seized bottom brackets are a pretty common problem on older frames, I would generally suggest to disassemble any donor frame completely before you use it to find potential problems. Maybe you can still get it out though, it's usually just a problem of finding a way to apply enough torque

[@wam8963]

I love it! The square shape, the paint, it is awsome. You Real did a great job, thanx for sharing.

[@irmacabrera742]

@Kamban Master as

[@muellermade4857]

This is fantastic! You are the person who first inspired me to want to make a cargo bike with your originall bike build on on Reddit all those years ago. Please make more videos!

[@adamthethird4753]

Excellent video and even better plans. Thank you very much for all the work you put into this. I plan on building at least two of these. Good health to you!

[@rubartknas7075]

Großartig-kenne kein besseres Video zum Thema-Vielen Dank für Deine Mühe und die Einblicke in Deine erprobten Handgriffe.

[@CraigsWorkshop]

Great bike, great video. The voiceover worked really well. I learned loads of tips and tricks. Thanks Phil! Craig

[@moth.monster]

I like how you showed how to make the steering shaft without a lathe.

[@beratsesigur3970]

amazing building skills, so much fun to watch,beautiful job

[@randybecker55]

This video made me smile from beginning to end! 😊 You sir think outside the box ... are an incredible engineer ... and a master craftsman! Your extra attention to detail is what makes what you're doing so enjoyable to watch! Keep inventing ... and PLEASE ... keep making videos! And the things you can carry on this bike!! WOW! 😂 LOVE IT!! Keep up the good work!! 👍

[@eatenkate]

Really liking the voice-over!

[@iplayzthegames6968]

Honestly this is incredible. I always wanted to get an ebike to commute but there's no way I'm taking a car full of tools on my bike, I reckon I could easily fit most of my tools on that, asides maybe a chop saw. Definitely gonna have to look into building one of these for the summer

[@muzzelc]

Quality video Phil. Love your work!

[@selivokhin]

Great video, built mine own according to this and now i'm one happy cargobike owner! Thanks Phil!!!

[@franks.5069]

Definitely diggin' the voice over. It helps to learn why stuff is made the way it is.

[@mikk01975]

Excellent video! Lot of skill and hard work there 💪 A Bullitt framekit is around 1600€ and for someone who has no access to a workshop, let alone any skills in the area, it just might be the cheapest option 😅

[@michaelangelosuarez3201]

nice work...truly nice work.what i admire most from you DIY guys is the patience & ingenuity...

[@travelingkaspersworld4096]

Great work! You make it look easy. We can tell it took a lot of thinking to get you this far! Very well done!

[@leonclose7823]

Great video. I built a really rough bike of this type several years ago. Now that my circumstances actually suit a cargo bike, I may have to build another. Just bought your plans.

[@xrayaiz74]

This is a very useful idea and a great project tutorial. Your choices are very practical and fit very well with the design goal. I also like the option to make the bike an electric variant. Just great options on this one idea of a modified bicycle. These would be great to have in auto assembly plants for skilled tradesmen to use and get some exercise in. Thanks again for your great design knowledge and fabrication skill.

[@shawnhayden6674]

I loved this build! Fantastic work.

[@kamoke1]

Beautiful job, very thorough video, thanks for going through all the work for us.

[@juliodifelippo]

Wow. What a video. Sooo great. Of course I want more. Saludos!

[@Handcraftedrock]

I've been building bikes for years. I think my built quality looks like crap comparing to yours. This is a professional bike manufacturing. Excellent craftsmanship.

[@rxsamar]

I found you first build years ago - this video is fantastic - nice work and thanks for sharing

[@obybenkenoby]

Oh Mann! Danke! So eine tolle Anleitung. Unkompliziert, Sympathisch gut gemacht!!!

[@diyowl5496]

34:20 - Such a casual cut. Nice build though, I have to say your welding skills are impressive!

[@abdrazak6963]

Love this. So much possibility and endless potentials. Well made and well done 👍.

[@woodinheart]

Meins ist am Sonntag fertig geworden. Danke für die Pläne und für das Video.

[@robertfreund7525]

Great, perfect job. Love that bike. Keep up that great job.

[@ConiferProject]

I was wondering when you build a cargo bike 👍 very cool :)

[@KarolisBorkertas]

So sick I would love to have one !

[@persimonsen8792]

Buy one www.larryvsharry.com/

[@chris.s1678]

This is just the type video I am after to help with building my own cargo bike! Thanks very informative and helpful!

[@weijia8088]

Great video....looking forward to seeing your future builds

[@gabrielharris1845]

I like this design. I might make this with my everlast welder once the weather clears up a bit.

[@PhilVandelay]

Since these questions come up a lot: - The final weight of the whole bike is about 30 Kilograms in my case. Obviously this will differ slightly between builds depending on parts and materials. - No you don't need a motor to ride it, the effort required isn't that much higher than a normal bike unless you're going uphill with lots of cargo. - Yes it's easy to ride, you get used to the handling after a few minutes.

[@CONQUISTADOR79]

Phil Vandelay by far this is the coolest bike man thank you for the inspiration stay blessed brethren

[@stefanludwig275]

Very impressive build. I watched the whole video and think about to build one by my own. You think you also can build it from aluminum with higher wall thickness of the tubes?

[@PhilVandelay]

@@stefanludwig275 Yeah I have considered that as well. I think the construction would translate well to Aluminum, 2mm walls would probably be enough as it's already quite overbuilt. I mainly went with steel because it's more common and you can use it with most welders

[@stefanludwig275]

@@PhilVandelay Why you removed the downtube from the mountainbike frame? You dont think that you have more stiffness if you use the whole frame? Another thing, i think you are german, right? Than we also could write in german :-)

[@celsocsouza9206]

Phil Vandelay

[@grumpygrandpa3640]

Got my parts all ordered up found two bikes ordered the plans and found a really nice industrial storage box for the cargo bay, never welded before but I’m sure I’ll get the hang of it with a little practice it’s not a race so I can just take my time. THANKS SO MUCH 👍👍👍👍

[@PhilVandelay]

Always glad to hear that! It'll be a rewarding experience 👍

[@anythingelectric5209]

Absolutely make more! Bro, you opened my eyes to endless possibilities! Thanks

[@slimsqde7397]

this is so cool, i would be carrying so much stuff everywhere lmao

[@oletrenner]

Great build, great video! Now I want a cargo bike...

[@brunobatistaalves7774]

LoL Me too!

[@rbadlon613]

Superb ingenuity! Thumbs up for you sir!

[@nickwinn7812]

Just the perfect amount of detail in the explanation. Great bike.

[@Amsterdam767]

Лучшая инструкция по созданию карго! Всё до мелочей Спасибо, мужик

[@user-qh8og3ci3e]

водка путин дом2

[@JefGaLingVlog]

I like your work Man👍😊

[@alfateh1650]

Wow

[@themanofquality3582]

yes I am also from Indonesia🇮🇩👋👍

[@jlucasound]

That is an incredible design and build. Kudos to you! You could even attach a comfy seat (I'm talking Lazy Boy Recliner-ish!) to the platform and mobilize a disabled person or anyone, for that matter. The electric idea is very tantalizing!

[@arlindocarvalho256]

Hi! You are the big one! Congratulations!! Thank's for share! This Project is Amazing!!! Greetings from Brazil!!!

[@mothertruckerpodcast6133]

0:14 Ms. Frizzle: "ok class the school sold our bus so now we have to use our imaginations on the trip, speaking of which we are going to explore the great lakes."

[@user-gz3yt9wg7s]

The sponsor joke got me subscribing 🤘

[@fwmtb]

same

[@RCAVDH]

Thanks for sharing! Great job !

[@TheSmartCat1]

What a great job mate. Beautyfull!

[@davidhughes4722]

did anyone else see the giant bus driving through the pond at the beginning 0:16?

[@MaxImagination]

@vortexrider1 A bus. :)

[@AllanJoChristiansen]

Is this in København Denmark Lol

[@MikeJones-wq4qv]

@vortexrider1 Hamburg

[@admiralicywolffeyt1465]

It actually a boat. It just looks like a bus I think I might have been whoooooshed

[@Friek555]

kzbin.info/www/bejne/nX3Flniwqd2knJI Here you are ;)

[@TheLaXandro]

>The most important thing you need is motivation and you can’t buy that Well, I guess I'm shit outta luck here

[@simonafloat]

This is great. I will be buying your plans really soon and look forward to building!

[@cheeseburger12D2]

I really like this project. Great job editing as well. Very entertaining.

[@Rouverius]

10:34 RIP. But as an American I can say, it was was worth it though. :D

[@mohitjoc25]

Make more vedios like this love from india

[@niteshgowda8995]

Which state

[@macacotaradao]

Your attention to detail is remarkable... Thanks for a well build product....

[@rosstruss]

Amazing job, thank you for sharing Phil...

[@BruceBusby]

Had you considered using aluminum for the bike and cargo frame? Great job, love the colour. I'll be making something similar this winter

[@BenMitro]

I was thinking the same thing. One can strengthen the aluminium by judicious use of steel flat bar on either side of square hollow aluminium to get the strength only in the plane that it is required to keep the whole thing light. I was thinking that the flat bar can be attached to the aluminium hollow with stainless bolts and spacers to minimise galvanic corrosion.

[@PhilVandelay]

I have made aluminum bikes before, but for this one I wanted to keep it simple so it's accessible to more people. And most hobby shops don't have the equipment to weld Aluminum. But yeah, it would save a bunch of weight.

[@tonyjenkins7156]

Hybrid of steel welded with aluminum riveted is an option to reduce a bit of weight. I build a camper for a Toyota pickup out of steel, have been reducing its weight by replacing piece's with aluminium. (I welded joints from steel and rivet aluminum tubes to those).

[@roningtr]

I ve watched the whole video. this is why I pay for my internet

[@abzcabz9211]

do you know internet license is one thing thats free for mankind it shouldnt be charging money that means your paying for something belongs to you thanks to the inventer and founder

[@roningtr]

@@abzcabz9211 who should I make a lawsuit against?

[@MattOckendon]

The build plans are worth every penny, thanks Phil

[@rolandocrisostomo2003]

You are a great teacher, your voice is perfect for step by step fallowing , keep up the good work. I

[@dantheman1896]

“The most important thing you need is motivation and you can’t buy that”

[@niclaslofgren]

17:15 was that a Diresta referens ?!

[@PhilVandelay]

It was :)

[@andreasp6694]

If it sounds like a Diresta reference, it is a Diresta reference... And btw: the voice over is a nice mix-up imo. Nice vid!

[@arifrobihidayat]

The new video format more informative, i think. Its so Helpful

[@user-ld1ys7pv6h]

Excellent precis job, love your work!!

[@hazmatader2836]

17:12 If it looks flat it is flat, reminded me of my classmate girl

[@nicolasschmmit8508]

shortest 40 minutes ever xD

[@juanmapagan3947]

Didnt even notice it was 40 minutes till you mentioned it!!! Lovely!

[@carlos2004]

@@juanmapagan3947 same, watched the whole thing and didn't even look first that it was 40 min. granted, now i watch almost everything in 2x speed but still counts i think

[@puckibort6601]

Perfekte Produktion. Beides

[@cinarsinan]

I watched it again and again..

[@juliuspantoja1636]

P

[@just1voice994]

I really enjoyed watching your video. I am not going to build one but still enjoyed watching it. You have a calm intelligent way of speaking which is great. Thanks

[@jethrogauld7437]

Thank you so much. Definitely saving this for a future build.

[@charlesharwell6480]

Dude this video and the cargo bike are awesome!!!

[@DanielNit]

That is some pretty solid and damn awesome video! A lot of work went into preparation, with an earlier prototype and a glorious outcome. Thanks for sharing!

[@solobi2010]

this is wonderfull great job PHIL

[@elluisito000]

What an amazing video, thanks for sharing.

[@fatsolutions]

This is some brilliant work Phil

[@scottingleman8103]

This is the first video of yours I've ever seen ! Nice work! I need to buy as 55 gallon barrel of motivation!

[@3DIYOriginal]

Love the Way you work, Awesome Video !!!

[@royalewithcheese1000]

My favorite video on all of KZbin. Thanks, bro.

[@plunder1956]

It's such a useful idea. A trailer can do some of this quite well. This style of Dutch or Danish Cargo Bike is very flexible. When I was a kid in the 60s, I saw many of them in Denmark carrying crates of beer LOL. I even saw an old one here in the UK. With modern Electric assistance they would be very practical even for people like me.

[@f1rstclass596]

Great build. I love the sofa attached.

[@briangordon9168]

Brilliant tutorial 👏🙏i wish others can learn from your simplicity

[@UisamG]

Love the voice over. Great job! keep doing it. Regards from Argentina.