Camper Project - Bike Rack
What is being done?
The time has come for the first of many camper projects. This time, I’ll be outfitting my popup camper with a receiver hitch to allow the use of a bike rack while in tow. This would be very easy for larger RVs since they typically have a 4″x4″ bumper with many choices of bike racks aftermarket. However, the standard popup camper bumper is only 1″x3″, which hardly offers an easy solution.
What is the plan?
the bumper is slightly offset from it rail mounts as they are only 1″x2″ leaving approximately 1″ gap between the bottom of the bumper and the side rails. It was decided to purchase an 1/8″ thick 2″x2″ square pipe to be fitted across from side rail to side rail. To account for the gap mentioned previously, grooves will be cut lengthwise in the square pipe and the pipe will be fitted tightly to each side rail. After the pipe is positioned, small spot welding will add to the strength of the new bar. With the new bar in place, there are now two points to which a receiver hitch can be mounted giving it the strength we need to support 200 lbs of bicycles.
What we need to purchase?
2″x2″ steel square pipe 52 inches long, Sawzall blades for cutting through metal pipe like butter, and a receiver hitch combo bar. The combo bar is similar to a hitch extension, but is only the receiver portion straight through. I found this at etrailer.com in 6″, 8″, 12″, and 18″ versions in their Fabrication section. The 18″ was my choice since it would leave plenty of room for cutting away excess if necessary.
Steps
- cut support pipe to fit between side rails
- measure distance between bottom of side rails and bottom of bumper, then cut a 1″ groove (1/8″ thick) that distance from the bottom of the pipe
- cut through one side rail near the rear bumper to allow access to slide the new support into place
- once in position, make spot welds to assure to movement and good bond with side rails
- weld the cut made in the one side rail to put bumper back into original position
- put spare tire back into place, then clamp hitch receiver into position
- put empty bike rack into receiver hitch to check for clearance
- adjust receiver distance from end of bumper as necessary allowing for full access to bike rack pins
- remove bike rack and spare tire
- weld receiver hitch into place
- for added support, run a bolt up through the receiver hitch and the support bar
- sand bumper
- paint with high gloss black paint
Pictures
before project
new support bar resting across side rails.
Support bar is now welded in place.
Receiver hitch ready for installation
Receiver hitch installed and painted
Bike rack fits nicely in the new receiver — I know I painted this sloppily
Let’s go camping!!
Project Summary
The project was a success. I now have a place for my bikes when I’m hauling my camper. Most of the time was spent waiting for the hitch receiver to arrive, but as projects go this one went pretty quickly. There are a couple things I would have done differently. I should have ordered the hitch receiver before starting the project, but at that the time, I had no idea the fabrication receivers existed. The other thing would be to tape off the camper rear before spraying the bumper and hitch receiver. It shouldn’t be that hard to remove the paint as it is not that much, but it could have easily been avoided had I taped off that area.
Myrtha said,
Wrote on July 10, 2007 @ 8:32 pm
Look like you’re having a ton of fun with your new pop-up. Cool web site too. Striking, then I find out you do this for a living. No wonder it looks so pro. Thanks for dropping by my site, www.JoyOfCamping.com. I’ll be back on this site, you write about some unusual stuff.
PopUp Camper said,
Wrote on February 14, 2008 @ 9:11 pm
Trey, I was thinking of adding a reciever for a bike rack to my popup like you did(Nice job btw). I have read it causes a lot of sway while towing. How did yours perform? Any noticeable sway?
Thx
cranst said,
Wrote on February 20, 2008 @ 9:56 pm
It does create a little more sway from the rear, but that really depends on the number of adult bikes you are carrying. When I only have one adult with two kids bikes, it had no sway. With two adult bikes, you can feel the trailer move from time to time. I’d also recommend adding a U-bolt to brace the receiver hitch to the bumper as a fail safe.
Colin said,
Wrote on June 17, 2008 @ 2:28 pm
Ok this is really interesting. I have the same issue as you. So I have some questions.
1) where did you get a welder? Are you just spot welding or truly welding all contact points?
2) Where did you learn to weld from? I’ve read most of your site and welding as a skillset I just don’t see you “picking up” along the way.
3) I’m almost certainly going to do this to my popup too. So the picture of how the receiver is mounted/welded/u-bolted isn’t clear enough for me. Can you provide a little better picture? It looks like the 2×2 is cut in half and the receiver joins it back together with welds.
Thanks!!
cranst said,
Wrote on June 17, 2008 @ 4:30 pm
A friend of mine owns a body shop and welding equipment. Together we did a poor job welding it though it seems to look okay. Ultimately, if you really want something strong, you’ll need to rebuild the rear bumper. I say this because you are welding a hitch receiver to a bumper that is at least half as thin. When doing a weld like that you definitely want to keep the two item roughly the same thickness. The initial weld didn’t withstand the stress of bouncing bikes for 100 miles. The second go ’round, we corrected the welds, and added a U-bolt that Us under the hitch receiver, goes through the bumper to bolt to the top of the bumper. I’ll take a better picture of this and post in as an update.
Colin said,
Wrote on June 17, 2008 @ 9:51 pm
Here’s some pix of mine.
http://www.arizonaed.com/images/camper1.jpg
http://www.arizonaed.com/images/camper2.jpg
http://www.arizonaed.com/images/camper3.jpg
Yes, to call the sheet metal a “bumper” is a stretch, agreed.
So the first attmept failed? Spectacularly or just in the driveway? Sounds like a good story.
I’m thinking of using unistrut instead especially since I’d have to pay someone to weld it. If things go really bad there is a welder for hire that I know of.
Trey, after reading your website, you sound like a Texas version of ME. Very strange reading your hobbies and stuff! hehe
Thanks
cranst said,
Wrote on June 18, 2008 @ 6:10 am
The first attempt failed in the last 4 miles of a 100-mile round trip. It wasn’t anything out of the Spy Hunter game dropping bikes behind my car. The outermost weld broke free after continual bouncing, and the rack just started leaning. The two adult bikes I had on the rack drug for about 100 feet before I realized what had happened. Two new tires and wheels, and a new weld with added reinforcement (U-bolt), the rack has held up nicely. I’ve been on at least two trips since then with a full set of bikes.
So if you are a version of me, can I assume that you, too, have a blog that gets neglected sometimes?
Colin said,
Wrote on June 18, 2008 @ 8:40 am
Blog >> Well no, no blogs for me. But 20 years ago I had a bbs which was severely neglected. Does that count?
I think the unistrut will be my solution. No need to weld just bolt everything together. Obviously welding is more secure but I can’t do what I ain’t got.
Have you tried building your own tivo yet? Myth works on ubuntu ya know.
Colin said,
Wrote on June 19, 2008 @ 10:05 pm
Well I’m now thinking why “rig” anything? Perhaps a cheap hitch brought to a welder along with the popup is the best solution. Stay tuned.
Thanks.