technology workshop craft home food play outside costumes

Basic Multi-Modular Frames for Cargo Bikes - Stackable watertight laser cut
boxes
by Velo M2 on September 19, 2015

Table of Contents

Basic Multi-Modular Frames for Cargo Bikes - Stackable watertight laser cut boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: Basic Multi-Modular Frames for Cargo Bikes - Stackable watertight laser cut boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 2: Download the lasercutting templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3: Download aditional lasercutting templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 4: Lasercutter preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 5: Laser cut ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 6: Chamfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 7: Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 8: Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

http://www.instructables.com/id/Basic-Multi-Modular-Frames-for-Cargo-Bikes-Stackab/
 Author:Velo M2 Vélo M²
The cargo bike is a great alternative for the car in congested cities; with our stackable modules we give sustainable initiatives endless possibilities. Vélo M²
(pronounced Vélo em carree) is a multi modular capsule system fitting on cargo bikes. With our energy module supplied by solar and pedal power you can
have the electricity on location to power an open-air cinema, a mobile fablab and much more on top. We bring all these plans to an open source platform and
community where anybody can contribute. Cargo Bikes can be used for more then only transport, with Vélo M2 we give the tools to rethink how we interact,
move and use energy.

Intro: Basic Multi-Modular Frames for Cargo Bikes - Stackable watertight laser cut boxes
The basic multi-modular frames for cargo bikes is the first building block in our open source platform Vélo M², an ecosystem where we provide the electricity by solar &
pedal power and the plans to build modules to your imagination that make use of this renewable energy. We want to make use of cargo bike by adding mobile fablabs,
open air cinema, foodbikes, … . If you want a nice-looking stackable watertight laser cut box just to transport all kind of things or to give a place for your module idea or to
immediately start building our self sustainable energy module, you first have to go through this building part.

In this documentation you will find everything to make a 450 by 650 mm base with different heights (150, 300 or 450 mm). The realisation of the content of the module
itself will follow. If you want to find more about how the inside frame works and how you can arrange all kind of modules, you will find our two examples in the near future:
A raspberry-pi based open air cinéma & a mobile open-source fablab

SKILLS NEEDED

Laser Cutting
Basic Woodworking skills

REQUIREMENTS
One person
Laser Cutter with at least a 70 on 50 cm dimension
Chamfer Machine

LEVEL

Intermediate

TIME

Total time estimate: half-day work

20 minutes for preparation of the wood parts

25 minutes for file and laser cutter preparation
45 minutes of Laser Cutting + extra time for Fase 2
40 minutes chamfering the grooves
20 minutes sanding + extra time for Fase 2
20 minutes varnishing the wood
30 minutes assembly

COSTS

Materials: €40 – 70
Fablab Day Pass €20 – 50

INPUT
Sheet of Plywood for the frame
Water-resistant
10mm
Dimensions: 1700 x 1220
Sheet of Plywood for the arrangement walls
Water-resistant
10mm
Dimensions: depending your application of the module
Varnish

OUTPUT

One 450 x 650 on 300 mm Basic Multi-Modular Frames for Cargo Bikes

http://www.instructables.com/id/Basic-Multi-Modular-Frames-for-Cargo-Bikes-Stackab/
Step 1: Preparation
Gather the materials

Not all plywood can be laser cut. Make sure your plywood is interior grade with an MR glue line. Check here for details on the materials.
Sheet of Plywood for the frame
Water-resistant
10mm
Dimensions: 1700 x 1220
Sheet of Plywood for the arrangement walls
Water-resistant
9mm
Dimensions: depending your application of the module
Varnish for the finishing of the wood and to make it watertight.

Get the tools

If you have a FabLab nearby, you have all the tools you need.
Laser cutter with min 100W power and dimensions of min 650x450mm
Chamfer machine with chamfer head of 10mm diameter

Step 2: Download the lasercutting templates

The lasercutting templates provide the cutting lines for 10mm plywood. If the plywood is less or more than 10mm, the plans should be adapted.

File Downloads

bottom.dxf (4 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'bottom.dxf']

side2_30.dxf (6 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'side2_30.dxf']

sides1_30.dxf (6 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'sides1_30.dxf']

balk_pl2.dxf (2 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'balk_pl2.dxf']

balk_pl1.dxf (2 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'balk_pl1.dxf']

handle2.dxf (5 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'handle2.dxf']

handle1.dxf (6 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'handle1.dxf']
http://www.instructables.com/id/Basic-Multi-Modular-Frames-for-Cargo-Bikes-Stackab/
 mid_plate_2_30.dxf (3 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'mid_plate_2_30.dxf']

mid_plate_1_30.dxf (4 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'mid_plate_1_30.dxf']
Step 3: Download aditional lasercutting templates
For other sizes than 300mm height, download the additional templates and follow the same logic.

File Downloads

sides2_45.dxf (5 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'sides2_45.dxf']

sides2_15.dxf (8 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'sides2_15.dxf']

sides1_45.dxf (4 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'sides1_45.dxf']

sides1_15.dxf (8 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'sides1_15.dxf']

mid_plate_2_45.dxf (3 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'mid_plate_2_45.dxf']

mid_plate_2_15.dxf (3 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'mid_plate_2_15.dxf']

mid_plate_1_15.dxf (3 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'mid_plate_1_15.dxf']

mid_plate_1_45.dxf (4 KB)
[NOTE: When saving, if you see .tmp as the file ext, rename it to 'mid_plate_1_45.dxf']
Step 4: Lasercutter preparation
Prepare and set the parameters of the Laser Cutter to cut through 10mm plywood. Check you parameters and make a few test to find the good settings. This is
dependent on the type of machine.

http://www.instructables.com/id/Basic-Multi-Modular-Frames-for-Cargo-Bikes-Stackab/
Step 5: Laser cut !
Laser cut the nine elements following the Laser Cutter DXF files.

For a box of 300mm high use the templates:

In 10mm plywood:

bottom one time

side1_30 two times
side2_30 two times
balk_pl1 two times
balk_pl2 two times
handle1 two times
handle2 two times

In 9mm plywood:

mid_plate_1_30 two times (or more)

mid_plate_2_30 two times (or more)

The wood will be burned on the sides, that's why it needs to be sanded later on.

Step 6: Chamfer
Chamfer the side plates following the grooves engravings. The grooves are there to fit the mid plates that allow to make compartiments in the boxes. They are placed
every 5cm over the whole length of the side plates. Use a 10mm chamfer head to make the grooves.

http://www.instructables.com/id/Basic-Multi-Modular-Frames-for-Cargo-Bikes-Stackab/
Step 7: Finishing
Sanding

The sanding makes the boxes nice looking. The wood burn should be sanded to prevent to black color to be spread. The grooves should be sanded to allow the mid
plates to slide in easily.

Varnishing

The varnish makes te boxes watertight. Apply two layers of wood varnish to each element. Check the instructions that are dependent of the type of varnish.

http://www.instructables.com/id/Basic-Multi-Modular-Frames-for-Cargo-Bikes-Stackab/
 Step 8: Assemble
Assemble the box following the laser cut indications.

1. Fix the side plates and the bottom plate with screws in the laser cut holes.
2. Have fun assembling the module to your own ‘goesting’ (cf. Most beautiful Dutch word of 2004)
3. Fix the top borders to the sides to hold the second frame on top.

Now you have the frame ready to fill it in to your own imagination. What would you take outside with a cargo bike, knowing you have an energy source?

Related Instructables

how to build a
Cargo bike / Ice Cargo Rack Kiddie Bike 2 Wheeled
cargo bike by Bike (Sport
Cream Bike by Trailer, all Cargo Bike from
You don't need carkat Hauler) by old mountain
mick bull grown up by
a car, just the Woodenbikes jxross bike frame by
right bike. by nthomas12
Random23

Advertisements

Comments
1 comments Add Comment

tomatoskins says: Sep 23, 2015. 8:16 AM REPLY

This is great! I love the look of those boxes!

http://www.instructables.com/id/Basic-Multi-Modular-Frames-for-Cargo-Bikes-Stackab/