Welding a steel rack to a steel frame
I ride a Marin Larkspur.
My current rack is aluminum and is fine for my current uses and the connection to the frame is a threaded hole in the dropout, not a braze-on.
That said, if anything were to go wrong, I think the weak link is the 2 M5 bolts that attach the rack to the dropout.
I've wondered if a custom steel rack welded onto the frame would spread the load more evenly as there are no more bolts to consider.
If anyone has ever done this, or considered doing this, would love to hear about it. Also not sure if it would be better to go with brazing or TIG welding. I'm thinking 3 vertical/diagonal tubes to the dropout, and one to the seatstay - or would that be overkill?
Here are some of my considerations:
- I would just purchase a midtail bike with a built-in rack, but it will not fit into an elevator. My current bike with a rack fits into an elevator with room to spare.
- There are few viable options for purchasing anything off the shelf, so custom is the best route and there are a few framebuilders who could do the job. I haven't consulted with them yet and am seeking experiences doing this first.
- My current rack is rated for 25 kg. The Surly rear rack is rated for 36 kg but sits higher than I would like. I don't foresee transporting past 50 kgs on smooth road over a short distance, so I'd love a rack solution that could support that. Time will come when my kid weighs more than 25 kgs and I'd still like to be able to take him around. Interestingly, the cost of a custom rack and having it welded to the frame might cost just as much as a Surly rack.
- I'm currently running on 27.5 x 2.5 hookworms and they're plenty stable.
- Trailers are not an option I can realistically consider due to storage space.