I built this Sturdy Front Rack by Modifying a $25 Bending Tool!

[@EdwardJoy]

Lmao "With a modified $25 bending tool! (And a full machine shop, welder, and decades of experience)" 😂 Excellent fab work, nice rack!

[@tballew]

lol right? "... especially considering I used the cheapest tool possible" and a mill, lathe, TIG welder, fixturing table, bench vise, machinists vise, drill press vise, band saw, belt sander, hydraulic press, sand blaster, countless hand tools, and custom jigs and spacers 😆

[@Fetherko]

+ CAD Software ​@@tballew

[@Penofhell]

My thoughts exactly haha. Titles says "with a 25 bucks tool" then goes on to show pristine welding table, TIG welder, milling machine, bandsaw and so on. Although to be fair @Fetherko Fusion360 is free for hobby use. I would have recommended Onshape for stuff like this because it makes it much easier to share designs... And let's be honest, Onshape is better than F360, I'm not scared of the pitchforks !

[@keinschwein8467]

More racks (and also the paintjobs ... and more bike components in general)! Now want to see you do one in thin-walled crmo tubing.

[@0mu488]

Aye!

[@NottinghamshireNick]

I’d love to see an episode of painting bikes please. Loved the build.

[@Brian18741]

No real interest in bikes but I've watched all you bike videos, i love the engineering, fabrication and problem solving. Excellent work as always. 👌👍

[@OperationDarkside]

Yes, more bike accessories, please. I rarely do metal work, but most stuff can be replicated with wood, so this is very interesting.

[@ebayerful]

especially the bending is easy with wood. oh wait :D

[@Cyromantik]

@@ebayerful Good point! I mean, you *can* bend wood, but you need a large steaming chamber and a form on which to bend the wood. On the other hand, rather than bending it's easier to just plan ahead and cut your wood in the shape you want and add reinforcement if needed. Bending metal is far quicker, cheaper and easier, but people build with wood because they like how it looks and feels, so it's not always about what's easier, I guess.

[@tryaluck]

As a pipefitter who has used loads of these benders and made quite a few, you did a really good job. If you make a mistake when bending, if it's just a small amount you can correct it with a heating torch. Heat a small spot on the outside of the bar or pipe on the side you need to pull out, then let it cool. Then repeat on the inside on the side you need to pull in, rinse and repeat until you get to the dimension you need. I've always called this technique ringing, but not sure if it's just the name that the guy who taught me, gave it.

[@kleckerklotz9620]

Yes, please. Show us how you paint bikes. Would love to see that.

[@msk3905]

Disassemble, put on a stand, sand smooth or down to bear metal if needed, if bare metal spray with metal etch then primer then paint following paint instructions. Lastly cover with clear coat.

[@paulwithers9194]

I wanna see cammo paint in action!

[@milvus6765]

I am delighted with your work. Well done, master. I will say one more thing - if I, like you, had this pipe bender break the first time, then in the next second it would already be lying in the trash. And you showed that any technical problem can be solved with an engineering approach. Once again - bravo.

[@leslieaustin151]

More bike accessories would be of interest here. This rack, for instance, is also relevant to motorcycle use with a few very small modifications. I’ve already made 3 racks for my motorbikes from 12mm steel tube, but solid alu is an attractive alternative. Thanks for the video and the ideas. Les in UK 🇬🇧

[@joshmofosho]

I am only half way through the video. I love cycling and machining.... and it is HILARIOUS watching you chase the issues through the project. Every time something happened I laughed and said "that's me right there. yup. exactly what i would've done" great video. I have been wanting to make some paniers/ racks because i also carry ridiculous things on my bike. this was fun and informative

[@xmetal280]

I love this project! Your craftsmanship is always top notch and I particularly enjoyed how you took a cheap tool and were able to modify it to your needs. Great work and really fun video to watch!

[@onewa712]

AMAAAZZIING job! you totally created like the best rack I've ever seen, and the bending tool that ended having like a quarter of its former self was hilarious 😂😂😂 awesome video and build

[@spinyuk]

'vice-ception' made me laugh. amazing work as ever!

[@EatMoreBananas]

Rack tangle

[@davegillett4036]

I’m here for the bike content! I’m also here for all the other content too. I really enjoy your approach to solving problems.

[@stewcrane3441]

Very pleasurable to watch you develop and build this.

[@campbellpaul]

If the weld is done right, it will be stronger than the base metal. You're a skilled fabricator to accomplish such good fit and finish on that part; subbed

[@AdmitthatijustdiditX]

My two worlds colliding is so satisfying! I've been thinking about machining projects at work, that can apply to bicycles, and racks were definitely the first thing I thought of! Truly enjoyed this video.

[@nicholascowlan7743]

The narrative is excellent, as is the engineering. Thanks for posting

[@marcellocapone4925]

Immaculate work, sir.

[@LordHolley]

Very nice job! Next time you use the bender, add some grease. It will bend far easier and minimize scoring.

[@PhilVandelay]

I did add some oil based lubricant (you can see it in some shots) but yeah, grease would probably work better

[@klasbjörnstedt]

Hello Phil. I built a front rack to my son in your type because the only good one to buy was so expansive. I built it with scrap irion. I test it with 10 kg on a bumpy track and it seems sturdy enough. I think the trick is holding the size down.. The raw meterial I use was 12 mm steel tube and flat bar for the rack. i used a similar dimension angle iron for the stretchers. I bent the tube with a spiral around a water pipe and weld everything together. The steel was free from a scrapbox in a metal work shop close to me. The only thing I had to buy was a bottle paint spray. Work time was 1.5 hour for cutting and welding. I am not a good welder so the afterwork with grinding, finishing and so was around 3 hours.. the weight is just over 1 kg. So what I mean, your way is very complicated. But you have my love and respect beacause I guess ypu like the project and your rack looks better than mine. And i like your video. Metal working is not my thing. I like wood and some of my projects is sometime totally unnecessary. But I do it for fun. Best regards Klas from Sweden

[@kevinsimmons8351]

I would be interested in seeing a video about painting bike frames. I am hoping to re-paint my Surly this winter.

[@portmanteau.]

More bending projects in general would be cool.

[@TheAnimal191]

This video had lots of components I liked. It was frugal, innovative, resourceful, practical and it solved a real world problem. Excellent. More bicycle content is very welcome!

[@robertomalatesta6604]

I wanna go frugal; by me a tig welder, a welding table, a lathe, a mlling machine, a bandsaw and oh yes a 25$ hand bender. 😁

[@relampagowheelery]

You never fail to impress Phil. More, this is my place of calm -- I watch the videos and I think I hear myself humming "A-oooooooom..." every time something is milled. LOL! Yes to painting bikes Please -- the one thing I completely dislike mostly due to the effort and how often a rattle can approach simply does not ever last coupled with its general toxic nastiness. I dream of an in-house powder coating situation at shop Re:Ciclos, but I'd love to hear your thoughts on this in general. Thank you always Hermano!

[@guywihn1658]

I'd be very interested in a bike painting video. Nice job with the rack!

[@slicedbread9003]

I had a bike that I was experimenting with at one time. While I wanted to paint it, I was changing too many things to do so. I had a buddy that was a duck hunter and he camouflaged his stuff with camo tape. So, I bought some and taped over the frame of the bike. It wasn't bad. Nice job on the rack. That is the reason for checking out this video. Cheap tools have a purpose and so does fail fast, learn and move on.

[@aimanapril24]

Love the inclusion of your problem solving. Top notch as always !

[@Bimp_Lizkit]

Love your philosophy on cheap tools. Completely agree. Its about expectations.

[@runningman4459]

Your engineering is second to none. Fantastic 👍🏼

[@richmond411]

What a fantastic channel for bike- and tinkering-nerds like me. Thanks!

[@matthewpeterson3329]

Great video. Most of the bike projects can be carried over to custom components for motorcycles and scooters. Who doesn't love a custom part. Thanks for the ideas, Phil.

[@longlog_cargo]

Richtig schönes Abenteuer ❤ Die Speichengeschichte zeigt mir, dass es gut ist, dass ich immer 2 Speichen im Lenkerinneren dabei hab. Hab mit dem Lenkerende als "Plätzchenausstecher" zwei Kreise aus ner alten Isomatte ausgestochen, die Speichen da durchgepieckst, und in den Lenker gesteckt. Klappert nicht, und fährt mit, bis ich sie mal (hoffentlich nie) brauche.

[@FPR]

I don't have a bike but I loved the video. I don't have any of the tools here, but I do have a dremel, and sometimes I have to make modifications to things I have or make small custom parts out of metal or wood, and the sense of accomplishment I get from doing so is hard to describe.

[@rinkinkel]

The bearings on the headstock are next to go. A heavy-duty rack like this is better mounted directly to the frame. Also, the weight of the load will influence the balance and steering less. Great video.

[@andyamos8594]

Brilliant! Almost totally reconstructing the "cheap" tube bending tool. And yes, at least cheap tool get you going and if they help you get a better idea of what you need when upgrading😀

[@williamschultz298]

Good to see that you're still alive and we would love a bike painting video!

[@howder1951]

Nice build and exquisite finishing, Very nice design with those threaded holes and solid rod. Enjoyed very much, cheers!

[@tmeinc]

Beautiful job! I also buy an economical tool and proceed to spend many hours making modifications and additions until it works. Then, having learned a great deal, I realize how to do the same job more easily using something I already have.

[@iphar]

Oh, my god! The rack came out absolutely gorgeous! 🤩 And I don't think you could have made it any sturdier while keeping the weight down; congratulations! The only think I would do differently is a coat of PU paint/varnish at the end. You've got so many nice tools.

[@pbsluvr312]

Thank you! You are an excellent teacher and skillful!

[@Nix_sound]

Superb build. I modified an aluminium rack recently to fit my needs, but I'd love to make the whole thing from scratch. I made the support arms from 10mm aluminium tubing and used easyaluminium weld rod, with a map gas torch. I'll be honest, I blew through one and had to remake it, but I think I learnt a lot about focusing the heat. I'd love to be able to weld. Great video, new sub added.

[@KrzychuSroka]

I am full of admiration for your work. I really enjoy working in the workshop and building bicycle equipment with my own hands. Respect :)

[@Infinitesimal-ho7it]

Yes, make more videos about painting bikes and more accessories!

[@carlneville2088]

A man after my own heart. Spending untold hours making a tool to improve something . When you could have bought a thing that woud do the job for 5 bucks on ebay.

[@garygerard4290]

Cool video - I love making due with materials/tools. I'd think a few drops of oil would reduce drag on the tool.

[@Biru_to]

​@@garygerard4290 watching the video, he sprayed copious amounts of something on the tool / material, probably oil. 😊

[@garygerard4290]

@@Biru_to I saw that later on after posting my comment - thanks

[@ricardoaraujo5223]

This is the first time that I have seen your video but to me is excellent, thank you very much for this ideas specially for the light location. Congratulations. Go ahead..

[@paullydca]

I'd love to see more bike accessory builds. Great rack solution, looks amazing.

[@DaveMcIver]

Great innovation, great skill and excellent outcome. Always enjoy your videos Phil. Keep them coming!!

[@branchandfoundry560]

Clean end product and as you say, a good learning experience. That's a solid win!

[@Ukuleleal]

Excellent video. The rack looks great, but the thing I enjoyed most was how you solved each problem as they arose. Just off to check your other videos. 🙏

[@geraldevans2688]

Love that German Craftsmenship,excellent job.

[@rodrigolopezmaya5974]

Bro I really like your videos they give me peace of mind at the same time I am learning new stuff. I would love a Workshop tour

[@riverlovejoyi1497]

Exactly my philosophy about trying out cheap tools as well and doing some mods. Thanks!

[@joshuaanothereraseddad]

First video I've encountered of yours and you definitely provided some good chuckles. Many thanks!

[@Neudezign]

I'm a bike nerd and I would absolutely love to see more bike content. The rack turned out beautifully, nice work 👍✌️

[@simoncornelis9240]

I do stainless steel pipe bending in factories for a living for a few months and it's actually easier to measure and bend the tube one bend at a time from left to right. It involves less math and the tool is less likely to hit other bends. The follower die on my tool has two wheels and markings to visualise where the pipe will end up after bending it. Which facilitate grandly the process

[@Dutcharmytent]

I made a similar front rack last year, using M8 studding , comes in 3 metres lengths from most electrical outlets. Used to hold up cable trays. I used the same bending tool. I also used M8 connectors and several assorted M8 EURO clamps on the stem and handle bars all very cheap. Bolts together. No welding. Made six racks so far.

[@secondlifebikes80]

Awesome workmanship!

[@shane0clock716]

One of my favorite things is watching how machinists and fabricators approach and overbuild solutions to problems in their hobbies.

[@tal121966]

Looks so much better than my Allyn diamond front rack. And is obviously much stronger. Great work!

[@nikfish1]

I cannot believe you have such a well equiped shop, and a temu pipe bender lol. Nice job!

[@garywilliams2375]

Something to consider regarding paint. The step on my Range Rover was forever getting scuffed and worn through where my foot falls. I found that the best paint by far was the High Temperature Barbeque spray paint from Lidl. Tough as anything and cheap, The rack looks great BTW

[@ALAPINO]

As a fellow machinist, I approve of this debauchery. 😅

[@cushmfg]

That looks REALLY nice. well done

[@curtisbullock9739]

Love seeing this process! Great work!

[@superfrog7429]

Love your video's, for my last holiday I also had to build my own rack to fit on a fox 36. I used 10mm by 2mm aluminium tubing very strong did some enduro tricks with it. I used a cheap bender for copper tubing an polished the channeling of the bender and aplyed some grease worked verry goed and no scratches

[@Eskatologist]

I just love you videos... informative and interesting... not sure I care enough about paint to watch painting specific videos, but knowing your videos they'll probably be better than watching paint dry... ;)

[@bricklearns]

Yes! I’ll watch any and all bike and tool stuff you make

[@garyjones2582]

Very nice work Phil.. I love to watch people build things that think outside the box.. I'm interested in purchasing a missile silo and would love to hire people like you that have great fabrication skills... Phil thx for bringing us along on your adventures.. Take care my friend and God Bless....

[@fulljackrackoboe]

Lovely! Anything related to building bikes or stuff for bikes will be more than welcome.

[@mheermance]

The rack is gorgeous. Great work

[@1111757]

i'd love some more rack building content! i might also buy plans. bike racks are stupidly expensive and usually don't even fit well so i've always wanted to build diy bike racks for all my bikes.

[@yetzt]

Your videos always brighten up the day :)

[@Noman3]

Yes to more bike accessories, and bike paint job videos!

[@il_missionario_della_dopa]

Nice build and explanation, thank you for uploading. First time I see your vids… just subscribed.

[@mrclize]

This camo paint job is sick! I'd love to learn how to do that

[@harrycaul2494]

Superb work and great video and explanation, thank you !

[@CreativeFishDesignsCharlotte]

is Def a graval bike , i thought I was the only one , hunting and cycling got to love it man , thank you for the how too I will be using

[@GarishMotley]

vice-ception is just perfection there, bravo

[@mozismobile]

Definitely a fan of DIY bike racks and would like to see more accessories that I can copy :)

[@davidmcconnon2800]

great job. Love a bit of aluminium machining.

[@BradleyShannon]

Could you please do a short on how you did what looks like use recycled inner tubes in the rack to secure things? Thanks!

[@matthewmoilanen787]

As usual Phil an exelent solution to an annoying problem. Super nice and tidy work as is your way. Always looking for fun little projects to do aren't you Phil.

[@charlesissleepy]

If the paint fails, you have a perfect opportunity to learn how to anodize aluminum

[@robwgeorge]

Awesome job. Yes to bike painting. Yes to more bike accessories. Thank you.

[@TheKing669]

Yes bring all the bike ideas you have! Love your videos.

[@connormcadams6387]

Ive been looking to go through a similar process for my bikes! I cant tell you how much this has helped! thanks!

[@lectro5418]

Nice. Power back on in 5 days, not bad. Back in 89, we were with out power 11 days , my parents were without 34 days. I feel for you a bit. Get use to it more coming. THIS episode power was off only 15 hours. As a lineman, my grandson goes around the nation restoring power

[@nickdubois8218]

I don't care what your video is about necessarily. I'll watch it regardless :). Good job with the drill chuck while milling! Trigger engaged

[@jean-pierremartineau4136]

Nice rack, and nice bike. Looks like the ultimate do--it-all and it doesn't warrant too much attention

[@stevenclease6500]

Great build, I'd love to see more.

[@MakeEverything]

Nice work!

[@2000bvz]

I love all things bikes, so more please! And I am in the middle of painting my bike right now, so... a video on painting would be great even if it comes too late for my specific project. I also dream of learning how to machine someday. And as to welding well... I started building one of your cargo bikes from the plans I bought from etsy... but apparently I am not good enough at welding yet. I kept burning through the cromoly walls of the donor bike (both trying MIG and TIG). I am signed up for a follow up welding lab session (the only place I can get access to a welder) where I can try it again. So my fingers are crossed that I will someday have my own cargo bike. Anyway, I love these videos. Please keep them coming! Thanks

[@vinyltheif]

Looking great! Although I was surprised you hadn't machine (or filed) a concave on the end-faces of the cross-pieces

[@versus023]

great video! Love so see more of bike accessoire et bike paint for sure!

[@rickbartley9255]

Very nice result!

[@air-bud]

I've always liked the adjustability of the nitto m18 rack with solid struts, but never really liked the size of the rack or the flat mounting plates as it just never looks elegant enough. Your solutions with this rack were very nice. Good job with the build! I want to see more of your rack designs. Check out pass & stow racks for some design inspiration.

[@richard-j]

Really nice. Been thinking about something similar. Bigger than yours, but smaller than the mega-basket I now have on my Orbea e-Katu. Thank you for the inspiration, and great video. 👍

[@lokinya]

Nice work! I still don't understand how front racks got so popular and totally dismiss the one in the back, though. The first thing I did when I bought my new bike was to remove the bulky front rack and install a proper one on the back of my bike for removable bike bags. On the steering bar, I mounted some rubber lined pipe clamps on both sides with hooks to hang large grocery bags from. I can haul a lot with that setup. :)

[@PhilVandelay]

For me it's mostly that I never trust my stuff to actually stay on the rear rack especially on bumpy rides. If it's in front of you, you can see what it's doing and even readjust stuff when it shifts during riding. The other part is a question of style I guess, I can't put my finger on it but front racks just look better to me

[@Crackdown77]

Sir you have some real good skills! And good tools too, needless to say. I'm interested in more bike accessories vids. Ciao from Italy