Building a transition rack. How to drill holes and crimp legs?

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2010-05-27 4:26 PM

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Master
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Subject: Building a transition rack. How to drill holes and crimp legs?
After setting up at the KC Tri last weekend I am thinking about building my own transition rack.

They were (appeared to be) EMT pipes.  The cross members had holes cut in an X-pattern, and the legs were crimped such that the crossmember would not slip below them.

The legs fit inside the larger pipe for storage.  Pretty simple and effective.

1/2" pipe for legs, and the beams were probably 2".

Anyone make these before?  How to go about drilling the 4 holes in each end for the legs, and how to make the crimps in the legs?

I'd love to make one of these for myself.  Great for practice, and one or two sets would be awesome for a casual race with a small group.

The pipes should cost not much more than $20 per set. (Not including any drill bits/hole saws etc.)

2010-05-28 6:55 AM
in reply to: #2887074

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Expert
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Apex, NC
Subject: RE: Building a transition rack. How to drill holes and crimp legs?
I just use a sawhorse.  Not much investment, and about the right height.
2010-05-28 8:30 AM
in reply to: #2887915

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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
fgump - 2010-05-28 6:55 AM I just use a sawhorse.  Not much investment, and about the right height.


My sawhorses are like waist high. How small of a bike do you ride?

These are the racks we use at most of the local tris. The end pieces each consist of a 2x4 upright and a 1x4 base, with the uproght nailed at a 90° angle in th middle of the base. At the top of the upright a hole is cut just a bit bigger than the galvanized pipe used as a crossbar, like a 1-1/2" hole for a 1-1/4" pipe. Makes for a very sturdy rack, and maybe cheaper and easier to make than the all-pipe rack you are describing. A little more difficult to store/transport though.



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2010-05-28 12:39 PM
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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
I used 1 10' piece of 1-1/2" EMT and 2 1/2"x10' pieces of EMT. To drill the holes I used a 3/4" metal hole saw predrilling with a smaller size drill bit than the pilot. I drilled the initial hole straight thru each side to make it easier, then used the hole saw to enlage the hole on each side. The holes should be not be too far from off center of each other. Try to line up the holes on the other side and repeat. I cut the 1/2x10" in half for the legs. I just picked a spot 12" down and used a hammer to dent each side. My first attempt is not perfect but with some adjusting it works fine. I think that the getting the legs adjusted in the holes is the key more than getting the holes perfect.  Go to racesmith.com for picture reference.
2010-05-28 1:32 PM
in reply to: #2888915

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Master
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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
bmxsykes - 2010-05-28 12:39 PM  I think that the getting the legs adjusted in the holes is the key more than getting the holes perfect.  Go to racesmith.com for picture reference.


I found those pics last night.

Same concept, except at the race the ones I set up didn't have couplers. They would make for straighter lines, but I think they'd just add unnecessary work in assembly and storage. 

Theirs actually are 3 different sizes, with the cross member being an even bigger pipe with an inner diameter that fits the size the coupler is made of.  No doubt more rigid, but obviously more work and more pieces to deal with.

I think I might try to make one with PVC first.  There's no way it would be strong enough for a 10' span full of bikes, but I think a short one for 1 or 2 bikes would work.  The plastic would be a LOT easier to drill and figure out the angles on for sure.

-eric
2010-05-28 4:06 PM
in reply to: #2887074


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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
The couplers are not needed. The only have those so that the main beam meets shipping dimmensions easier. The regular 10' version has the holes drilled in the main beam. The totale cost of mine was $17 from Home Depot. I think even 2" pvc will sag at 4'. Depends on the weight of your bikes and if the front tire rest on the ground.

2010-05-28 10:46 PM
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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
huh?   WTF?   why would anyone bother to do this?
2010-05-28 11:12 PM
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Elite
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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
Yeah, they had a setup like this at XTERRA King of the Hill with PVC. Worked great. They just slid the pipes out the holes, took off the end cap of the PVC and stored the pipes inside the PVC. They were temporarily using duct tape on the pipes to keep them from sliding, but were planning on welding washers on for a permanent fix. You could probably get away with drilling a hole and putting a dowel pin through the hole, then cotter pins through that pin to keep it in place.

2010-07-15 8:55 AM
in reply to: #2887074

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Expert
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Apex, NC
Subject: RE: Building a transition rack. How to drill holes and crimp legs?
For those that questioned my sawhorse transition rack, I took this last night after a brick I did.

2011-09-10 11:30 PM
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Master
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Subject: RE: Building a transition rack. How to drill holes and crimp legs?

Holy moly that was harder than I thought it would be.

I bought enough supplies to make 2 today and set to work. The first set of holes went fine.  When I put another set on the other end, well that's when the fun started.  Couldn't get symmetry/balance on the darn thing.  I somehow got the second set of holes on a different axis or something.  I made ANOTHER set of holes on one end and it didn't get much better.

I set about starting over for the next try and I made a LOT of measurements. I used masking tape to transfer marks along the pipe and a chalkline to extend to the other end.  This gave me MUCH more precise angles but that wasn't the entire battle.

I lined everything up better with more thought, but because of the angles involved the hole-saw didn't quite line up a big enough opening and I pretty much had to open up most of the holes a bit. Quality time with Mr. Dremel....

Anywhos,  first attempt (or 3rd to be more specific) is on the right and the better result on the left.

2011-09-10 11:36 PM
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Expert
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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
I just lean my bike against my car...

2011-09-11 7:02 AM
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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
fgump - 2010-07-15 9:55 AMFor those that questioned my sawhorse transition rack, I took this last night after a brick I did.

Your saw horse is too high.
2013-07-15 11:12 PM
in reply to: TriMyBest


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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
If you do a Rev3 event, they just use 2x4s that are on the ground that are just wide enough and long enough for your back tire. Much simpler concept and pretty impressive looking.
2021-04-28 9:55 PM
in reply to: kagoscuba


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Subject: RE: Building a transition rack. How to drill holes and crimp legs?
Originally posted by kagoscuba

huh?   WTF?   why would anyone bother to do this?

You're right. I was supposed to this but I back out before the event. I just realized how hilarious to do this transition rack since my legs do not have enough strength.

(*enjoyed reading old threads
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