Build the rear carrier transport box yourself
We were really impressed by our winter test with a transport box on the trailer hitch. Thus, the plan was clear, the summer vacation already tackle a lot more storage space. We have compiled our requirements briefly below for you.
What do we want to achieve with a rear carrier
The declared goal is to be able to camp independently for several days without having to deal with larger spaces. That means the tailgate needs to be opened. For rear carrier or so-called backbox transport system can easily be spent 600 to 900 euros. Our goal was to stay under 300 euros. The transport box must be operable, even if bicycles are transported on the rear bicycle carrier. This limits above all the height of the transport boxes. The rear carrier should ideally be able to be mounted alone and a payload of at least 30 kg should be possible.
Search for the coupling carrier
Most of the research time was spent on the ideal clutch carrier. Here I am also on the following great contribution encountered, which can use the box also flexible. A look is definitely worth it. Because even here I have to choose between the following options: platform support, box carrier system or a bicycle rack. Most platform and box carrier systems do not offer a possibility of turning, pulling out or folding to open the tailgate of the VW bus. Therefore, it quickly became clear that the bike carrier for the trailer hitch is the right choice. But even here it is not easy to find those that also fit for camper vans with large tailgate. In principle, following my research, the following are possible:
- EUFAB 11523 Premium 2 Plus Coupling carrier
- ATERA STRADA DL 3 Delux bike carrier
- THULE EURO >However, in July, the publishers published an additional note that read as follows: Feedback from customers is increasing (July 2017) that with newly approved VW T6 with removable trailer hitch ex factory no bike carrier for the trailer hitch the tailgate opening allowed. Therefore, we must currently assume that something has been changed to vehicle / clutch here. Therefore, you have to expect in the VW T6 that the tailgate with loaded bike carrier is not open – and thus no carrier on the market.
Regardless, the mentioned model ranked between 368 and 430 euros. Thus, these were already excluded, since you needed not much cheaper to have.
Then I read through the post again, where we tested the rear carrier for the first time. Here was a model of Primavelo Pro Alu used. This has definitely fit perfectly and the tailgate could be opened after folding the boxes. The only thing that bothered me personally was the coupler, which had plastic guides that are very delicate. In the search results on Ebay classified ads came quickly the other models. So also the steel: Primavelo Pro
The original bicycle carrier Heckträger Primavelo Pro
The shopping list for the rear carrier with transport boxes
- 1 Primavelo Pro bike carrier for 2 bikes from 50 Euro
- 2 aluminum boxes Alutec Munich A81 from 108 euros
- 4 locks for the aluminum boxes from 28 euros
- 2 aluminum strut profile 40x16mm 1700mm Nut8I from 17 euros
- 4 profile covers 40x16mm Nut8I from 1,60 Euro
- 8 slot nut with bridge N8I from 7 Euro
- 10 M8 screws 20mm from 4 Euro
- 12 M8 washers from 3 Euro
- 1 U-profile 1500mm 10x10x2mm from 5 Euro
- 1 M12 wing nut from 3 Euro
- Threaded rod M12 1000mm 4 Euro
In total, less shipping costs less than 250 euros.
Disassembly of the bike carrier
However, the carrier is by default too narrow (under 30 cm) for standard aluminum boxes. Or the lighting unit has to be moved.
Without shifting the lighting unit, the maximum depth of the transport boxes is limited to 26 cm.
The bracket for fixing the bicycle frame is easily reused.
The sawn-off pipes could simply be screwed to the existing structure through an additional hole and the existing screws and connectors. Then the lighting unit can be mounted again at the desired distance.
Assembly of the rear carrier transport box
The aluminum profiles are also fastened to the carrier with the existing screws and nut instead of the aluminum rails for the bicycles. But do not forget to introduce the M8 nuts for fixing the aluminum boxes.
Fixation of the aluminum profiles over the existing holes for the bicycle rails.
The fact that the boxes are not really stable and stand on an aluminum edge, the transport box can not be easily screwed. A small U-profile from the hardware store provides a remedy.
Balance the distance between the folded edge and the bottom with a U-profile.
Measure the holes clean, so that they have the appropriate distance to the aluminum rails and then drill. The same applies to the custom-fit aluminum profile. Now, the sliding blocks can be pushed into the correct position and the aluminum boxes are simply fixed with the M8 screws.
Maximum distribution of forces through large washers.
Now the back wall is fixed over the existing construction. This would ideally be a bit higher, but hopefully with a payload of 15 kg per side, that should be possible.
Last but not least, the wing nut is replaced by the angled pipe with nut, so that the tailgate really rises. Instead of the handles, we screwed the threaded rod with the angled pipe in order to fold the carrier faster. Now only the following parts are left.
During the last test, I was shocked to find out that the tailgate is not quite open, because the rear carrier can not be completely folded. I’m scared at first. But after a short investigation of the facts, it was a little bit of work on the square profile.
Shortening of the carrier so that the tailgate can be opened. After dismantling the bike carrier and conversion to the transport carrier, only the following small parts are left. These are the other parts of the bike rack that are a bit bigger.
Holiday we come
We will now test the self-built rear carrier with transport boxes on our holiday in Corsica. We will share our first experiences with you here. If you already have experiences and or suggestions and questions, I look forward to your feedback.
I was too cocky and have cut off too much when cutting off the 4-edge profile, so that the wearer can completely fold down. This has been temporarily fixed for the holidays.
In the boxes so much fit in that we had on the bus only a bag with provisions, one with electrical equipment and a tank bag.
Since the wild camping was really fun, because in addition to the flip up from the bed and the fold over the bed, there was hardly anything to rearrange. Ok, we still have the booster seats of the children who have found their place in the driver’s seat.
Driving through the many and loaded to the weight limit, the aluminum profiles on which the boxes are, slightly bent. Here I would go to square next time. The boxes can not be completely opened with folded bike carrier and must be kept, which also offers potential for optimization. The next time I would not shorten the 4-kant tube so generously. Then the additional construction for a stop would be omitted. I’ll probably replace it with a damper on occasion. So, there is not much to optimize in my opinion. Just try it and send a comment if you have any questions …
- More space without unnecessary requests for swimsuits or games under the seats or in the bus
- Parasols and other accessories such as fishing rods and paddles can also be attached
- A compact car in everyday life
- It can not be transported snowboards or skis (here I think about something else
- In combination with a long rear extension (greater than 70 cm) it can no longer be used relaxed.
Hello, looks great, the same I plan, especially for longer holidays you need a lot of luggage. Have more awning, camping chairs e.c. thought, which could be stowed in the rear box ……………..
My question: I have with the rebuilt, of course, stable bike rack to obtain TÜV for operating license.
What does our police say about that?.
Hi Rüdiger, yes with the permission is an exciting topic and was discussed in this post already hot. My conclusion from the discussion is that the operating license must show that not only bicycles but also loads can be transported. In my certificate from the carrier is rear load carrier, but I sent another mail to the security vendor for security, but still received no feedback. If you can contribute new knowledge here I would be happy.
I like your solution very well. Have only one question: Can you still open the tailgate with high-folding roof and mounted bikes?
Thanks and regards
So with 1-2 wheels, I’ll flip it up a bit, if I need something from the trunk, but in this review is also a link to harder dampers for the tailgate. If you try it out then please send me a few pictures in folded up position and let me know if you can close the trunk lid when it is unloaded
Thank you for the great guide.
I rebuilt it that way, with primavelo pro for 40 € and a self-made aluminum box measuring 140x48x45cm.
Works really great with fold down and tailgate open on t5.2 cali beach.
The comments regarding the traffic law suitability from the other article I read later. I think the whole thing makes a very good and stable impression and do not intend to go to the TUV to let me forbid.
Hello Andre, I am very happy that I could inspire you with the ideas for the transport box. How did you do the aluminum box yourself? Welded or folded and riveted? Would be happy about some pictures. Because a box clearly has the advantage that in winter, the snowboards can be easily transported. Thanks for your feedback and best regards Christoph
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