Fig. B: Bend the sheet metal parts in a bending brake.
Fig. C: Rivet the body temporarily to the end caps, and
1" holes in the caps. Fig. D: Glob glazing putty onto the end caps, then pop-rivet every hole.
Fig. E: Clamp the trunk lip inside the body, level or
angled a bit downward, then drill and rivet it in place.
Fig. F: Drill and rivet the base to the body, then drill
¼" holes for the clips that will hold it on your rack.
6. Cut out and mount the door.
Cut templates A1/A2 and C1/C2 apart as indicated,
tape them in place on the trunk, and trace them
with a marker. Then use a Dremel tool to cut out the
door A2 and the hinge joint between C1 and C2.
Cut a ¼" gap between C1 and C2 for the hinge,
then clamp on the hinge, mark and drill through its
mounting holes, and pop-rivet it in place.
Use a Dremel to widen the gap between door
A2 and trunk A1 to
1". Bend the trunk lip D1 to fit
inside A1, level or angled just slightly downward
(Figure E). Clamp it in place, then drill and rivet in
place, backing the rivets with washers.
7. Mount the base and the latches.
Drill the tabs around the underside of the trunk
1" holes 1" apart. Fit the trunk over the base,
then mark and drill matching holes in the aluminum. Put a bead of silicone glue between the
panels over the holes, and rivet the base in place.
Wipe excess silicone with a rag and let dry.
Place the 2 hasps, one on each side. Mark and
drill through the mounting holes, then rivet the
hasps in place using the larger,
6" bit and rivets,
reinforced with washers.
Drill a hole for the brass knob on top of the door.
For decorative tailpiece E1, position it on the door
and mark and drill
1" holes in both pieces, but
don’t rivet it on yet.
7" pipe clips around the tubing on either
side of the bike rack platform. Flip the trunk upside
down and center the bike rack on the base (Figure F).
Mark the clip mounting hole positions and drill 4 corresponding ¼" holes in the base, plus an extra hole
centered in back where the rack already has a hole.
8. Paint and finish.
Paint the inside of the trunk flat black. Sand down
the putty on the exterior, then paint it with primer
and white paint (to keep cool in the sun). I cut
“College Bike Trunk” emblems out of black tape
and stuck them to the sides. Finally, pop-rivet the
tail on, and stick the red reflector on the back.
Install your new bike trunk on the rack using the
¼- 20 bolts. To lock the trunk, use padlocks with
shackles 1½" long, one on each latch.
Now you’re done. It’s time to celebrate like a
college student — go to the store, and pick up
Frank E. Yost is an amateur artist living in Andover, Minn.