Bike luggage rack design and development.
Hello people, this is Ruturaj Lonkar (B.E. Mechanical). Recently I have designed and manufactured a luggage carrying rack for my bike. Below is a overview of the design and manufacturing process. I did a market survey for the available racks and their load carrying capacity. The cheapest one had load carrying capacity of 10 Kg and costed around Rs.1500. The cost was too high for the product and what's the fun in directly buying. So, I decided to design and manufacture my own rack. Design: So the need for the design was to carry luggage on my bike for long rides, also to carry luggage when shopping solo. The mounting point was a constraint for me, so was the bolt size, due to the tapping present in the chassis. So I made a rough sketch of the packaging and made the corresponding FBD and BMD for the rack. And iterated the max load that the bolts can take. It came out that I can make the rack with max.30 Kg load carrying capacity with current holes and packaging setup. It was hard ...