Interior Bike Rack Write-Up (Lots of Pics)

[jangoforhire]

I figured it was time for me to join the cool kids out there and try and do some form of a write up. So here we go! My first mod (excluding the interior LED's and Z4 stubby antenna).

Interior Bike Rack
NOTE: CLICK ON ALL PICTURES FOR HIGHER RES VERSIONS
I apologize for bad pictures. But taking them with my iPhone and having
them waiting on my computer via iCloud when I write this is just too convenient.

So my goal here was to build a bike rack that would enable me to:
1. Keep my bike out of the weather
2. Not lose a tremendous amount of cargo space
3. Not have a permanently large bike mount in the middle of my cargo area

Parts I used:
<a href="http://www.amazon.com/gp/product/B000QV3NWU/ref=oh_o04_s01_i00_details">Thule Front Fork Mount</a> (you can find these for much cheaper if you shop around)
<a href="http://www.amazon.com/gp/product/B000KK989E/ref=oh_o05_s01_i00_details
">Quick Release Mount</a>

I got this idea after seeing a thread a while back about people using front fork clamps in the back and just removing them when they weren’t necessary. However, I didn’t need more than 1 clamp, and I also didn’t like the practice of temporarily clamping a 2x4 or something in the back whenever I need to transport my bike.

To fix this I came up with the idea of a quick release mechanism so the front fork clamp is only there when it is needed. Finding a low profile quick release mount that would work was a PITA. I finally found a GPS holder that looked very similar to something my dad uses on our sailboat. I got that from Amazon. The only other thing I needed was a Thule front clamp and I got that from Amazon as well. (The Amazon Prime deal for students is fantastic, free 2 day shipping on almost anything, I get all my stuff from there now)

Now, this isn’t terribly difficult, but figured I would take pictures for you guys anyway. I wanted the mount off to the side so I could transport my bike with two seats still folded up.



PART 1: Attaching the mount to the cargo tray.

I was a little scared to do this as I had yet to drill any holes in my new car! But I finally got my nerve up. I measured first, figured out the hardware I was going to use and went to town! I taped off the area, marked my holes and drilled. As far as hardware goes, I started a thread (here) a while ago about the best way to attach something to the rear cargo tray. I used some of the advice from the guys and used these connectors. I got them at my local hardware shop and they made the job very easy. (sorry for the exceptionally awful picture):
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/7.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/7.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>


Here is a shot of the pieces I used (left to right: Thule front fork clamp, base of the quick release mount, top of the quick release mount):
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/1.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/1.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>


Make sure you avoid the track when you drill:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/2.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/2.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>


Measuring the thickness of the tray was a bit arbitrary considering it has a lip all the way around. So I kind of had to guess with how long the screws needed to be. I ended up getting 3/4"tubes with 1/2" screws:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/3.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/3.jpg" width="248" height="480" border="1" alt="Bike Thumbnail" />
</a>


I put painters tape down to hold the carpet in place and so I could mark where I needed to drill:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/4.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/4.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>


You don't drill through the tray as much as you kind of "punch" through. The foam in the middle creates no resistance so you only need to punch through the top layer of plastic and the bottom layer of plastic. My drill made quick work of it.

Here is a shot of the holes from the top of the mat:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/5.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/5.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>


And under the mat:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/6.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/6.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>


Here is the mount secured from the top:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/8.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/8.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>


and secured from the bottom:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/9.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/9.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>



PART 2: Attaching the clamp to the mount.

Now that that part was taken care of, I just had to connect the Thule clamp to the top of the quick release mount. You can make this as easy or as hard as you want. I opted for the harder route as I want this to look as nice as possible.

Whenever I am not working on my car, I am in the wood shop, so I took the pieces down there and whipped up a little mounting piece for the clamp. Here are some pics of what I came up with.

First, the 4Runner parked right outside:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/14.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/14.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>

I used a small router to make a recessed mounting area for the clamp. Some of the lines aren't perfect but i free handed this with the router. And just as a note...

***NEVER FREE HAND A ROUTER. you should always use a table/jig/fence of some sort. I did it this time because it was a simple shape and I have been woodworking for over 12 years and am very comfortable with a low HP router such as this***

<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/10.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/10.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>

The clamp sits flush now:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/11.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/11.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>

Next I cut it so it would match the top mount of the quick release, and then rounded over the edges, sanded, and cut some other random angles to keep it interesting. I was literally making this up as I went.

Finished product before paint:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/13.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/13.jpg" width="640" height="478" border="1" alt="Bike Thumbnail" />
</a>



Time to paint it:

1 coat of primer
2 coats of semi-gloss black
3 coats of gloss clear sealer

Prep:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/15.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/15.jpg" width="359" height="480" border="1" alt="Bike Thumbnail" />
</a>

Black:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/16.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/16.jpg" width="359" height="480" border="1" alt="Bike Thumbnail" />
</a>


After the paint was done drying I just attached the two together. The I screwed the wood piece I made onto the mount from the bottom with wood screws (I will paint the bottom later):
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/17.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/17.jpg" width="640" height="480" border="1" alt="Bike Thumbnail" />
</a>

And then I placed the clamp in its position, drilled through the wood, and plastic of the mount, and secured the clamp with some bulbs and lock nuts. This was the only problem I ran into, I first attached the lock nuts on the bottom (as shown in the pictures) but had to reverse them to allow for the quick release to slide freely:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/18.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/18.jpg" width="640" height="480" border="1" alt="Bike Thumbnail" />
</a>


All done! (again, sorry of the blurry pics)
Also you can see the quick release tab in this picture at the bottom.


Finished product:
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/19.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/19.jpg" width="640" height="480" border="1" alt="Bike Thumbnail" />
</a>


With my bike mounted (That's my cycling bag off to the side there):
<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/20.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/20.jpg" width="640" height="480" border="1" alt="Bike Thumbnail" />
</a>

<a href="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/21.1.jpg" target="_blank">
<img src="http://dl.dropbox.com/u/58059700/4Runner/Bike%20Mount/21.jpg" width="640" height="480" border="1" alt="Bike Thumbnail" />
</a>


My final thoughts are that it works very well, but looks a little awkward. I have driver around with the bike for a while and the mount is surprisingly strong. There is some sway that I might fix at a later date, but I am happy with it's function and how the project turned out! I may alter the wood base I made later to cover the bottom of the quick release mount to make it look more smooth. But for not I am happy.

Hope this is helpful to someone! I definitely had fun making this. Let me know if you have any questions!

 

[Antman]

Nice idea- and great writeup!

I wish I had a wood-working shop like that.

PS- It's a requirement that T4R writeups have bad pics, so don't feel bad.:lmao:

 

[terra4r]

very nice, good write up. Killer shop too, i would love to have that!

 

[jangoforhire]

Thanks guys! Yea the shop is my favorite place to be when I am home. My dad taught me how to woodwork back when we had were crammed in a little garage. But since then we built a barn and moved all our equipment into it. The barn is actually modular construction from amish country and was originally designed to be a horse barn. But we had them remove the stalls so we have an open floor plan on the bottom for our tools and the top we can use for storing/drying wood. It's perfect.

 

[StuB]

Nice work and thread! The only improvement I see you could make to your whole "rig" there is if you had a Time RXR S Ulteam frame in there instead of that Super Six :wink2:

Incidentally, what size frame do you have there? Mine are 55 and 56s and my saddles all hit the roof when I tried them out upright like that.

 

[MarkWalker]

Excellent!

Nice and clean, and great idea on the QR base.

I have a Stumpjumper and have always hauled it with a fork mount. Made one for my Tundra, so the bike could ride right behind the cab, and now use a fork mount Hollywood rack.

 

[jangoforhire]

Nice work and thread! The only improvement I see you could make to your whole "rig" there is if you had a Time RXR S Ulteam frame in there instead of that Super Six :wink2:

Incidentally, what size frame do you have there? Mine are 55 and 56s and my saddles all hit the roof when I tried them out upright like that.

The frame is a 54, but I am shorter (5'8") so my seat post is lower than most. I have to angle the bike to squeeze it in there but it fits with about an inch to spare. I got lucky with the sizing of my bike.

Wow you ride nice! That is a pretty sick frame. My frame is actually the System Six as opposed to the Super. Still a great bike and I saved a few grand over the Super. Also It is one of the last System Six's Cannondale made in the US! It's a fantastic bike overall.

Nice and clean, and great idea on the QR base.

I have a Stumpjumper and have always hauled it with a fork mount. Made one for my Tundra, so the bike could ride right behind the cab, and now use a fork mount Hollywood rack.

I used to do the same thing with my old T100! I had to ditch the mount when I put a tool box in the back though. The bed was too short for both.

 

[StuB]

The frame is a 54, but I am shorter (5'8") so my seat post is lower than most. I have to angle the bike to squeeze it in there but it fits with about an inch to spare. I got lucky with the sizing of my bike.

Wow you ride nice! That is a pretty sick frame. My frame is actually the System Six as opposed to the Super. Still a great bike and I saved a few grand over the Super. Also It is one of the last System Six's Cannondale made in the US! It's a fantastic bike overall.




I used to do the same thing with my old T100! I had to ditch the mount when I put a tool box in the back though. The bed was too short for both.

The Time is my new baby. It is sweet if I'm permitted to gloat a little. It's shockingly better than my S-Works Tarmac SL-3 which is good because I would not have ever gotten over the "sticker shock" otherwise. I am only 6'0" but I have long legs and a short torso relative to my height. It makes bike sizing and fitting interesting and explains the two custom Davidsons in the garage as well. It is also why I can't even come close to transporting the bike upright inside my T4R TE even with the fork dropouts sitting directly on the cargo tray. A real bummer for sure.

Be sure you keep that nice US made beauty forever.

 

[diverdriver]

impressive workmanship..In my 3g I had two pieces of ply, one with two quick releases attached the other with three, two bikes lived in there for the summers, but on the odd occasion I maxed out at five bikes. Unloading 5 was like watching clowns getting out of a VW