shop drawings for a steel bicycle storage box
1 Project goal
Prepare a PDF package (shop drawings + assembly manual) for an improved version of my prototype bicycle box with a folding, upward-opening lid.
2 Input from me
Photos and a dimensioned sketch
3 Key requirements
| Area | Requirements |
|---|---|
| Structure | Steel frames made of closed profiles (preferred 40 × 40 × 2 mm S235 galvanised, but other sizes acceptable – I can buy additional stock). Walls, roof and lid clad with T7 trapezoidal sheet, 0.5 mm (specification – Blachotrapez). |
| Joints | Weld wherever practical; use bolts where welding is impossible/ill-advised. Each wall (left, right, rear) and the roof to be separate frames bolted together on site. |
| Lid mechanism | • Propose hinges and folding geometry. • Select and position a gas strut so opening/closing is light; lid must stay open unaided. |
| Locking | Robust lock, 1–2 locking points – please recommend a proven solution. |
| Anchoring | Box will stand on a concrete slab / paving. Provide base holes and specify chemical anchors. |
| Packing / transport | Split the design so main parts are ≤ 2.5 m long (roof preferably in one piece). Avoid unnecessary small items – keep parcel count reasonable. |
| Corrosion protection | After welding I will do local zinc-spray touch-ups; reflect this in details. |
| Documentation | 1) Assembly and exploded views 2) Part drawings with dimensions & holes 3) Bill of materials + fastener list 4) Step-by-step “IKEA-style” assembly manual (line graphics). All files in PDF (DWG/STEP welcome but optional). |
4 Your tasks
Analyse my sketch and prototype.
Optimise the design for strength and function (lid, hinges, gas strut).
Produce the full set of shop drawings and the assembly manual.
Project Brief – Bicycle Storage Box
Goal: Full set of shop drawings + IKEA-style assembly manual so I can fabricate an upgraded version of my prototype box at home.
Box size: ~2430 × 1265 × 1515 mm (see sketch). Minor deviations allowed.
Structure
Steel frames, preferred 40 × 40 × 2 mm S235 galvanised RHS (can be changed if justified).
Cladding: T7 trapezoidal sheet, 0.5 mm, Blachotrapez.
Each wall (left, right, rear) and roof as separate welded frames, bolted together on site.
Lid
Folding, upward-opening panel.
Engineer hinges + gas strut so the lid lifts easily and stays open.
Robust handle and lock (1- or 2-point).
Anchoring: Pre-drilled base plates for chemical anchors into concrete/pavers.
Packaging: Break the build into parts ≤ 2.5 m long; keep parcel count reasonable. Roof ideally one piece.
Corrosion touch-up: Detail local zinc-spray after welding.
Deliverables (PDF)
Assembly and exploded views.
Detail drawings of every part with dimensions, holes, weld symbols.
Bill of materials + fastener list.
Step-by-step line-art assembly guide.
Files: PDFs mandatory; DWG/STEP welcome.
