Long John Weld Repair

This was a really unusual job.  A guy came in with an obviously home-made long-john style cargo bike.  It was well designed and fabricated, with decently MIG or TIG welded frame, and a really professionally done steering linkage arm.  Nice 8-speed internal hub, and tractor-worthy brooks saddle.

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There was usually a plywood box on top of the front platform, where the rider kept his carpentry tools.

Anyway the “Boom Tube” which runs underneath the load had separated from its lower truss brace, immediately behind the front wheel.  The boom tube was cracking at the next junction back as well.  It had been ridden long enough to bend the tube, so some considerable re-alignment to both the boom tube and the lower truss was necessary before starting to weld.

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I was very happy to have a car-sized bay in the workshop.

(That handy heavy-duty small table has since been nabbed by scrappers…damn.)

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Welding went smoothly, I added a lot of material.  The bike was probably around 60 lbs.

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I put on a coat of black paint, then thoroughly tested it with two friends serving as cargo (~300lbs) on some heavily potholed test-tracks in the neighborhood.  Adequate, I think.