Trike Work Stand
Stand Design Goals
- Assembled from existing components with as little fabrication as possible
- Hold a trike horizontal at a level that supports working in either a standing and seated position
- Adjust to different trike brands and models
- Be mobile
The center of the front wheel is 35" off the ground.
The cost of materials for the stand as shown with shipping is about $200.
Aluminum Stand
The aluminum fittings are the key to creating the stand and the adjustable elbow in particular makes it possible to align the PVC supports to the trike's frame. The fact that the aluminum, PVC and wheel component dimensions fit together makes it seem custom designed.
The mobility supports the stand's work function but also makes it a storage rack that allows the trike to be moved around with unbelievable ease–it is where I keep my trike.
The aluminum parts can be ordered from the Diamond Aluminum Company. They will cut the pipe to specified lengths and ship everything to you. Web Site: www.diamond-aluminum.com
Phone: 513-821-1080
| Item | Size | Qty. | Unit Cost | Total |
|---|---|---|---|---|
| 1.25" Sch. 40 Aluminum Pipe | 27" | 1 | $7.00 | $7.00 |
| 1.25" Sch. 40 Aluminum Pipe | 24" | 3 | $6.25 | $18.75 |
| 1.25" Sch. 40 Aluminum Pipe | 15" | 1 | $4.25 | $4.25 |
| 100-PC Economy Tee | 1.25" | 3 | $7.50 | $22.50 |
| 200-PC Crossover | 1.25" | 1 | $12.75 | $12.75 |
| 106-PC Adjustable Elbow | 1.25" | 3 | $12.75 | $38.25 |
| PVC Supports (see below) | $10.75 | |||
| Caster City Wheels (see below) | $57.75 | |||
| Total Cost of Parts | $172.00 |
Note: Unit costs are rounded to the nearest $.25. Shipping is not included.
Wheels
The wheels that I specify below have locking mechanisms. The need for this can be debated. My original stand had only one locking wheel–the back wheel–that was used once to keep the stand from rolling away on a sloping surface. I do not typically lock the wheels when working on the trike. Some money can be saved by reducing the number of or eliminating the locking mechanisms.
The stem mount casters specified fit into the pipe, require no fabrication and provide an elegant solution. The actual interior diameter of the 1.25" schedule 40 aluminum pipe is 1-3/8".
The top casters are from Caster City and can be found on their Expanding Rubber Stem Casters web page (Item Number: D3ARG4X-ER25-ML, Stem - Swivel Caster with Total Locking Brake - Model 3A - Mounting Stem: ER25 Expanding Rubber for 1-3/8" ID pipe). The casters with 4" dia. wheels are $19.25 each and with shipping cost $68 for a set of three.
The locking mechanism stops the wheel from both rolling and turning. The casters roll easily, smoothly and quietly. They are overkill in terms of their load capacities and are expense but provide a beautiful solution.
A less expensive solution is from SES Casters and can be found on their Casters R29 Series web page (Item Number: CR29F04SXTX.RPFGGNX, Series R29 Light Medium Duty Expandable Stem, 1-3/8" ID pipe). The casters with 4" dia. wheels are $5.50 each and with shipping cost about $27 for a set of three.
The wheels roll smoothly. The locking mechanism only keeps the wheel from rolling as compared to the Caster City unit that keeps the wheel form both rolling and turning.
Also look at SES Casters series T39 for fully locking wheels at an economical price of about $8.00 each.
No Wheel Alternative
The functionality that wheels provide may not be of value to everyone. In the event that you do not want wheels, use a PVC 1/25" Slip Cap. These cost less that a dollar each making them the most economical alternative. File the end of the caps to remove the small raised burr left from their production.
This solution will lower the height of the stand by over 4." If this is of concern based on your height, add 4" to the length of the three 24" legs.
PVC Supports
The size of the specified PVC-Tee slip fittings is based on the size of the cross frame members used by Catrikes. If your trike has larger cross members, choose a larger PVC-Tee and the corresponding bushing to transition to the 1.25" PCV pipe.
The main member on the Catrike is larger than the cross member but I have chosen to use the same size Tee because it provides better clearance for the chain as it shifts on the back cassette. Make adjustments to fit your trike and its configuration.
Most hardware stores stock the PVC pipe and joints. You can usually purchase the pipe in 2' lengths. Only three 3" long pieces are needed. The PVC pieces can be put together without adhesive.
| Item | Size | Qty. | Unit Cost | Total |
|---|---|---|---|---|
| 1.25" PVC Pipe | 24" | 1 | $2.50 | $2.50 |
| PVC Tee Connector | 1.5" | 3 | $1.75 | $5.25 |
| PVC Bushing | 1.5" to 1.25" | 3 | $1.00 | $3.00 |
| Total Cost of Parts | $10.75 |
- Cut two PVC-Tees with the fence set at 1.125" (cut through center for front supports).
- Cut one PVC-Tee with the fence set at 1.5" (cut below center for back support).
- Trim the width of the Tees with the fence set at 1.25" (as close to stem as possible).
- Cut three sections of 1.25" PVC pipe at 3" long
- Sand all cut edges.
- Push a 3" section of pipe into a bushing and the bushing into a Tee.
- Stand the assembly on the cut edge of the Tee and hammer it completely together.
Note: When fabricating these for the PVC Plus Aluminum stand described below, the PVC bushings are not needed and the 3" pipe sections should be cut from 1.5" PVC pipe.
Aluminum Stand Assembly
Inspect the aluminum pipe for rough edges and the fittings for burrs that might keep the pipe from seating completely and smoothly into the fittings. I have found that some filing has been necessary on selected parts. Visually inspect or measure to make sure that the pipe completely seats in the fitting before you tighten the screws.
- Slip an Economy Tee on each of the three 24" pipe pieces (legs).
- Place the bottom edge of the tee at 11" from the bottom of two of the legs (front legs) and tighten the screws. Face the screws to the same side (front or back) of both legs.
- Place the bottom edge of the tee 12.75" from the bottom of the third leg (back leg) and tighten the screw.
- Slide one end of the 27" pipe into the tee on the back leg and tighten the screw. Set aside.
- Slide the Crossover fitting on to the 15" pipe. Do not tighten.
- Lay the front legs across two supports on a flat surface so the tee fittings do not touch anything and the legs are parallel.
- Slide the ends of the 15" pipe into the tees on the front legs and tighten the screws.
- Tighten the screws on the Crossover fitting against the underside of the 15" pipe to provide a little resistance.
- Slide the 27" piece of pipe that is attached to the back leg into the crossover fitting and tighten the screws to hold the pipe firmly. Make sure the back leg is vertical. Make the end of the pipe flush with the front end of the Crossover fitting–this is the position for larger trikes. You will adjust this later.
- With the three legs standing on a flat surface make sure that the front legs are vertical and the Crossover tee is centered between them.
- Tighten the screws that hold the Crossover fitting to the 15" pipe.
- Compress the rubber on the wheel stem so it must be forced into the end of the pipe. Finding the right degree of compression may take a few tries. The stem must fit tight enough into the pipe to allow it to be further tightened once inserted.
- Insert the wheel stems into the legs. I use a rubber mallet to help drive the stem into the leg.
- Turn the swivel bearing/nut to further compress the rubber and secure the stem within the leg.
- Tighten the bolts on the Adjustable Elbows so the can be moved with some resistance.
- Place the Adjustable Elbows on the top of the legs but do not tighten their screws.
- Place the fabricated PVC supports into the Adjustable Elbows but do not tighten the screws.
- Place the trike on the stand
- Adjust the angel of the elbows and supports so the PVC supports fit the angle of the trike frame.
- Tighten the screws and bolts.
- Loosen the screws in the Crossover fitting and push the back leg forward as required and retighten the screws and adjust the angle of the back support if required.
- Check the tightness of the screws in all joints.
Length Versus Level
Adjusting the distance between the front and back legs using the crossover fitting permits the stand to be adjusted to different size trikes. However, moving the back leg toward the front legs to accommodate a smaller trike will raise the back wheel. For example, moving the back leg in 3" raises the back wheel about a 2.5." The trike still feels relatively level and it does not make working on it more difficult so this may not be an issue for you.
The length of the back leg is set for a larger trike based on an Expedition. I choose to make all legs the same height for simplicity. Shorter trikes could use a shorter back leg to make the trike level. You could cut the back leg to fit a smaller trike or to provide a compromise between larger and smaller trikes. I would suggest working out the exact length using PVC pipe before cutting the aluminum pipe–I have made this mistake.
Catrike Length Estimates
An Expedition, 700, Speed and Trail have been placed on the stand to establish the dimensions shown in the table below. When a stand with a 24" back leg is shortened to accommodate a Trail it raised the back wheel about 2" above the front wheel. Therefore, the back leg is shortened for the Trail.
The "Crossover Horizontal" dimension in the table is measured from the front end of the crossover fitting to the inside surface of the back leg.
| Models | Crossover Horizontal | Back Leg |
|---|---|---|
| Expedition, 700, Speed, Road | 27" | 24" |
| Trail, Villager | 25" | 22" |
Given that not all pipe pieces fit into all joints perfectly and trikes vary in their dimensions, it will be necessary to use the crossover fitting to adjust the stand to make the trike exactly horizontal.
Terratrike
The Terratrike Cruiser works with a crossover horizontal dimension of 27" and a 24" back leg.
Original Aluminum Prototype
The first stand built with aluminum pipe used a piece of plywood as a base to which the stand and wheels were attached. This creates a surface that moves with the stand for holding tools and parts while working on the trike. The stand works well and with high quality 4" wheels rolls very easily.
The liability of this stand is that it only fits a single size trike and can not be adjusted.
I would recommend using a crossover fitting so the stand can be adjusted to hold your trike perfectly level before securing the back leg.
It would also be possible to leave the back leg unsecured to the plywood to retain size adjustment if all aluminum construction is used.
The additional parts needed to fabricate the base are provided in the table below.
Home Depot sells 2' x 4' sheets of plywood in a variety of qualities for under $20. This platform measures 24" by 36" and is tapered to 11" at the back.
When you deduct the Caster City Wheels you can see that the total cost of the stand has not changed significantly.
| Item | Size | Qty. | Unit Cost | Total |
|---|---|---|---|---|
| 150-S-PC Aluminum Rectangular Base | 1.25" | 3 | $8.25 | $24.75 |
| 3/4" Plywood Blocks (2'x4' piece, $20) | Cut | 1 | $2.00 | $20.00 |
| Plate Mount Locking Casters | 3" Dia. | 3 | $6.00 | $18.00 |
| Screws | 14 x 5/8" | 24 | $0.15 | $3.60 |
| Subtotal - Cost of Plywood Base Parts | $66.35 | |||
| Caster City Wheel Deduction (see above) | -$57.75 | |||
| Added Cost of Plywood Base | $8.60 |
PVC Plus Aluminum Stand
Constructing the work stand from a combination of 1.5" aluminum and PVC parts will reduce its cost. It requires more fabrication and results in a stand as shown to the left that is not as rigid as the all aluminum version but is acceptable.
The cost of the stand using the less expensive stem mounted wheels including shipping will be about $122 as itemized below. An all aluminum stand with the same wheels will run about $160. You get a much more rigid and higher quality stand for the additional $40.
The aluminum economy Tee fitting shown in the image was to allow me to adjust the distance between the legs.
A mitre box and saw will do a good job for cutting the PVC pipe.
| Item | Size | Qty. | Unit Cost | Total |
|---|---|---|---|---|
| 1.5" PVC Pipe (purchase one 10' length) | 27" | 1 | $5.00 | $5.00 |
| 1.5" PVC Pipe | 11" | 4 | ||
| 1.5" PVC Pipe | 13" | 1 | ||
| 1.5" PVC Pipe | 9" | 1 | ||
| 1.5" PVC Pipe | 14" | 1 | ||
| PVC Tee Connector | 1.5" | 3 | $2.00 | $6.00 |
| PVC Glue | 1 | $4.00 | $4.00 | |
| 200-PD Aluminum Crossover | 1.5" | 1 | $17.00 | $17.00 |
| 106-PD Aluminum Adjustable Elbow | 1.5" | 3 | $17.00 | $51.00 |
| PVC Supports (see above) | 3 | $3.00 | $9.00 | |
| SES Expanding Stem Mounted Casters (see above) | 3 | $10.00 | $30.00 | |
| Total Cost for Parts | $122.00 |
PVC Plus Aluminum Stand Assembly
Inspect the aluminum fittings for burrs that might keep the PVC pipe from seating completely and smoothly into the fittings. Sand the ends of the PVC pipe pieces after they are cut to remove and rough edges so they will fit fully into the PVC joints.
- Glue an 11" piece of PVC pipe into both ends of two PVC Tees to create the two front legs.
- Glue the 13" (bottom) and 9" (top) pieces of PVC pipe into a PVC Tee to create the back leg.
- Glue the 27" PVC pipe into the stem of the back leg.
- Glue the 14" PVC pipe into the stem of one of the front legs.
- Slide the Crossover fitting on to the 14" pipe. Do not tighten.
- Lay the front legs across two supports on a flat surface so the tee fittings do not touch anything.
- Glue the free end of the 14" pipe into the PVC tee on the other front leg. It is important that the two legs are parallel as once the glue sets you cannot adjust this relationship.
- Tighten the screws on the Crossover fitting against the underside of the 14" pipe to provide a little resistance.
- Slide the 27" piece of pipe that is attached to the back leg into the crossover fitting and tighten the screws to hold the pipe firmly. Make sure the back leg is vertical. Make the end of the pipe flush with the front end of the Crossover fitting–this is the position for larger trikes. You will adjust this later.
- With the three legs standing on a flat surface make sure that the front legs are vertical and the Crossover tee is centered between them.
- Tighten the screws on the Crossover fitting against the underside of the 14" pipe.
- Compress the rubber on the wheel stem so it must be forced into the end of the pipe. Finding the right degree of compression may take a few tries. The stem must fit tight enough into the pipe to allow it to be further tightened once inserted.
- Insert the wheel stems into the legs. I use a rubber mallet to help drive the stem into the leg.
- Turn the swivel bearing/nut to further compress the rubber and secure the stem within the leg.
- Tighten the bolts on the Adjustable Elbows so they can be moved with some resistance.
- Place the Adjustable Elbows on the top of the legs but do not tighten their screws
- Place the fabricated PVC supports into the Adjustable Elbows but do not tighten the screws.
- Place the trike on the stand
- Adjust the angel of the elbows and supports so the PVC supports fit the angle of the trike frame.
- Tighten the screws and bolts.
- Loosen the screws in the Crossover fitting and push the back leg forward until the trike sits level and retighten the screws. Adjust the angle of the back support if required.
- Check the tightness of the screws in all joints.