​​​​Scott Hansberry

This project was conceived while working toward my mechanical engineering technology degree. The construction will mainly be at CWU labs along with all analysis and testing throughout the year. The device will be built in sections with the two top arms build and then the bottom arm built and also the bottom bracket and top two brackets built. The top two arms will be cut to length while the bottom will be cut to six inch length and welded to the center of another tube cut to length of six inch be welded to form a T shape. The top bracket will be constructed using a flat 1/8 inch plate of steel and welding a hex bolt off the center. The bottom bracket will be constructed off a flat 1/8 inch piece of steel and have two vertical 1/8 flat piece at 55 degrees welded on and then a hole drilled through booth vertical pieces. The brackets will be clamp on using U shape bolts. Foam tube will be placed over the tips of the top arms and over the top to the T of the bottom arm to prevent the arms from scratching or denting the car’s trunk. The 6 stability straps will be replacement straps for preexisting bicycle car racks and will be attached directly to the bike frame with 4 on the top bar with 2 going to the top of the trunk and 1 going to each side and 2 on the bottom bar going to the bottom of the car. The hardest part was welding the aluminum since I never did it before and did a lot of practice welds with scrapes to insure I didn’t mess up and melt through my piece. Once all the parts were constructed and assembled and bolted to the bike I test fitted it on a car to insure the pedal or anything else didn’t interfere with the car.

​

One main manufacturing issue I had was getting the brackets on the top to fit flat and parallel against bottom of the top rail. Because the cables for the brake and shiftier run under the top frame I had to make shims and test fit them and then modify it by adding more or less shims to get both arms to be fit. once both arms were set right I welded the shims into place.