Plywood Nested Bike Rack

by noen, published

Plywood Nested Bike Rack by noen Nov 26, 2017


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498Views 113Downloads Found in Sport & Outdoors


These are the design files for the bike racks I built for my camp at Burning Man 2017.

You will need to use plywood that is 18mm/19mm or 23/32" or 3/4" in thickness. You should NOT use MDF, OSB or Particle Board. They do not have the rigidity needed for this design.

Pine or sande plywood are great inexpensive options. Use birch or maple as well, they provide a great visual finish.

These layouts are designed to be CNC cut with a 1/4" router bit, however you can also hand cut these using a jigsaw and a good palm sander. If hand cutting, be careful cutting the notches that join the pieces - they need to be very accurate to ensure a proper friction fit.

To assemble, use a soft mallet to push the notches fully together. It is easiest to start by attaching the cross-sections to the center piece, then setting it on the ground and attaching each smaller outer piece.

To disassemble, use a soft mallet to tap the pieces apart.

Read more about the design and the reasons I built it here: http://www.thetylergibson.com/building-a-better-portable-bike-rack/

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Hi -

This seems so Burnery-awesome that we are inclined to try it for our camp this year.

One other camper working on this with me had the comment that 3/4 ply is heavy, in quantity. Do you have any thoughts on that? Do you think that dimension was really needed, or would another (1/2”?) suffice?

I suspect this question is relevant primarily in conjunction with the weights experienced by camp strike teams, who will want to reduce the number of trips from rack location to truck by carrying multiple items.

You really need the 3/4" for rigidity. It took two people about 15 minutes to setup the 8 racks for our camp, and about 10 minutes to break them down and stack them. You're only going to be able to carry one rack between two people regardless of weight, even with 3/4" a rack only weights about 30 pounds making it really easy between two sets of hands.

Thanks for the prompt reply. We'll give it a whirl.

Great design! Did you treat the plywood with anything? How did it weather the playa for a week?

We used the cheapest untreated pine plywood (~$32 per sheet) and it stood up beautifully to the dust and dirt. I'll probably put some polyurethane on them next year just in case of rain, then they'd probably do well for a long time

It's cool and all but why is it here?

I needed a place to post the plans, any other sites more appropriate?