Lightweight Bicycle Camper Trailer

[skyl4rk]

I am building a lightweight bicycle camper trailer as a popup box using coroplast. I designed it with the idea of putting solar panels on top to charge an electric bike. I don't have an electric bike at the moment but I do have a gas powered bike, so I will use that and pedal power for now.

I designed it so the width is approximately the same as my handlebars with bar end mirrors, so about 36". The length of the bottom half is 86" and the top is 96". The frame was 27.5 lbs before adding the body. I have pulled the bare frame around through the neighborhood and it adds some drag but it is not bad and pulled straight.

When I started, I had no idea if it would work, but I took pictures and video. As of today, I have not completed it but it is ready to try an overnight sleep in it.
Here is the start of the project, the frame. It is based on the Paul Elkins style frame, but narrower.

Solar Bike Trailer Camper Frame
[youtube]0AwXvqDV-YM[/youtube]

I am using cheap kickstands as the trailer supports while sleeping in it. These are marginal, I think they work but don't have a lot of trust in them. If anyone has ideas for better supports, I am interested.

The 1" x 2" frame pieces were reinforced with fiberglass and epoxy at the joints. They seem to be strong enough but they flex. I think I would go with 2" x 2" on the long rails next time.

I need to find another way to get a towing arm, I don't think my self bent aluminum tent pole will last when the trailer is loaded.

My pictures seem to be too big to load.

 

[rjgimp]

I need to find another way to get a towing arm, I don't think my self bent aluminum tent pole will last when the trailer is loaded.

I have a two-seat kid hauler trailer. I believe the tow arm is made of steel tubing but at the end that connects to the rear axle of the bike there is about a 3" piece of coil spring to neutralize unfortunate forces that might otherwise damage the tubing.

 

[rjgimp]

skyl4rk, where are you located? I actually have a second identical trailer that I scavenged off a trash heap for the tires and axle but it has a complete tow arm also. You are welcome to it.

 

[skyl4rk]

I am in Michigan. I also have one of the kid trailers with a tow bar, but it is too short where it attaches to the trailer, I am hoping to find a way to make a longer tow bar.

 

[rjgimp]

Why is it too short? Do you have something else attached to the rear of the bike?

 

[skyl4rk]

Bike Camper Wheel Wells and Tub
[youtube]NwQSGgA7oRM[/youtube]

 

[skyl4rk]

Why is it too short? Do you have something else attached to the rear of the bike?

The part that attaches to the trailer is not very long, about 4 to 6 inches. I think I need a longer connection point to get leverage on my much longer trailer.

 

[skyl4rk]

Frame Reinforcement and Zip Tie Stitching
[youtube]cdCCwb0km6c[/youtube]

 

[skyl4rk]

Wheel Well Storage and Planning
[youtube]bADQNhc3_UM[/youtube]

 

[skyl4rk]

Shelves and Storage
[youtube]qne9fgKgoo8[/youtube]

 

[skyl4rk]

Bicycle Trailer Cap
[youtube]PqMrUuN7Q80[/youtube]

 

[skyl4rk]

Door Jams
[youtube]vz8_AeIobY8[/youtube]

 

[skyl4rk]

The Door
[youtube]OfKytDQyseU[/youtube]

I am looking for ideas on how to secure the door and to close in the gaps on either side.

 

[Tyrtill]

For closing the gaps If you want some ventilation I would use magnets and screen if you don’t want ventilation garage door seals do great on large gaps

weatherstripping

As far as securing do you mean locking or just keeping shut while moving?

I was thinking a light weight hasp with a keep people honest lock. Magnets once again make a good quick latch. Just be careful not to get ones that are too powerful

 

[rjgimp]

The tow bar I have is very similar in size and shape to the one you made out of the aluminum tent pole. I'll dig it out tomorrow and measure and send a picture.

 

[skyl4rk]

Here are two videos by Antonio Cruz with a pop up bike camper trailer that can be used with solar panels to charge an ebike:

[youtube]HQDJP6agg04[/youtube]

[youtube]hGwETm7AFFI[/youtube]

 

[skyl4rk]

Eventually when I get an ebike, I plan to put this 300W solar panel on the trailer:

https://www.amazon.com/DOKIO-Portable-F ... E8E83PZ3YX

The panels are 39" wide, so about 3" wider than the trailer. The panels are about 84" long, so less than the trailer cap's 96" length.

I will use this charge controller and set it at the proper current and voltage limits for the ebike battery, connecting the output directly to the battery.

https://www.amazon.com/Docooler%C2%AE-B ... E8E83PZ3YX

 

[skyl4rk]

As a rough estimate of performance, a 300W panel will produce about 900 Watt-hours per day, depending on shading, clouds and tilt angle of the panel.

I estimate that I can travel with a power use of 20 Watt-hours per mile, which means I could expect 45 miles of travel from solar power on an average day.

The 20 Watt-hours per mile estimate assumes that I am pedaling along with the motor, and that the speed is low, about 10 to 15 miles per hour.

I would expect to ride 3 to 4 hours a day to accomplish the 45 mile distance.

Here is a documentary of the Sun Trip, a race from France to China using solar powered bicycles:

[youtube]P1LB0jPh7QQ[/youtube]

Here is a spreadsheet with data on power use and distance traveled by some of the participants in the Sun Trip race:

https://docs.google.com/spreadsheets/d/ ... =858413259

 

[skyl4rk]

Here are two examples of electric bicycle motors that could be used:

This is a low cost, reliable hubmotor kit that would provide adequate performance in flat terrain, but would tend to heat up while climbing long hills:

https://www.amazon.com/Voilamart-Conver ... 176&sr=8-1

This is a more expensive mid-drive motor that would allow good hill climbing performance but may cause wear on the bicycle chain and drivetrain:

https://www.amazon.com/BAFANG-Conversio ... 07PZ7QS8Q/

A quality battery is essential to the electric bike system. This is a vendor with a good reputation for providing quality batteries. This battery would have adequate capacity and be a good choice:

https://em3ev.com/shop/em3ev-52v-14s5p- ... e-battery/

 

[greygoos]

Thanks for sharing your build. I am looking forward to the completed build.