Steel Bicycle Box Drawings

I built a very rough prototype of a steel bike box “on the fly”. It works, but:

it’s heavy and non-demountable,

transport is difficult,

assembly on site is slow,

the up-lifting split lid needs far less force.

I now need professional drawings so I can remake the box properly and repeat it in small series.

My Workshop & Materials (must be respected)
3 m bending brake for sheet metal
MIG/MAG + TIG welders
Cut-off saw for 6 m galvanised RHS

Profiles: 40 × 40 × 2 mm S235 galvanised closed sections (other Polish-stock profiles allowed if justified)

Cladding: Blachotrapez T7 trapezoidal sheet, 0.5 mm – no substitutes

Operations used: cutting, welding, riveting, bolting

All parts will be fabricated in Poland → only materials / fasteners available on the Polish market

What I Expect From You
Package content Details
Shop drawings (detailed) one card per part showing length, 45° mitre cuts, hole Ø & position, weld symbols, tolerances ±1 mm; cut-list optimised for 6 m stock; BOM incl. Polish part numbers
Assembly manual (simplified) IKEA-style line graphics or clean 3D screenshots; step-by-step order: frame welding → bolting → lid install → chemical anchoring
Lid mechanism propose hinges + gas strut (force, stroke, brackets) so the lid opens easily and stays open
Locking recommend robust 1–2-point lock available in PL
Packing logic split into sub-frames ≤ 2.5 m for courier shipping; roof preferably one piece
Deliverables PDF mandatory; DWG + STEP desirable; 1 round of revisions included
Deadline 14 calendar days from gig start

Reference Files Provided after hiring
Photos of the prototype (multiple angles, lid open/closed)

Dimensioned envelope sketch (~2430 × 1265 × 1515 mm)

Notes on weak points to improve



Freelancer Skills Needed
Structural steel design (Eurocode / practical workshop sense)

Advanced 3D CAD (SolidWorks, Inventor, Advance Steel, etc.)

Clear technical drafting

Experience with gas-strut lids / hinges is a plus

Looking forward to working with you!


Likely follow-up questions from a freelancer:

1. Do you already have a full 3D model of the prototype?
No. I only have photos and a dimensioned outline (2430 × 1265 × 1515 mm). Creating the 3D model is part of the job.

2. What design loads (wind / snow) should I assume?
The box will sit under a terrace canopy, so only self-weight and lid operation loads need to be considered. No formal structural calculations are required.

3. Are the 40 × 40 × 2 mm RHS profiles mandatory?
They are preferred because I already stock them, but you may suggest other profiles that are readily available from Polish suppliers if there is a clear benefit.

4. Do you need flattened patterns for the T7 sheets?
Yes. Show the flat length before bending plus the bend line so I can cut and bend on a 3 m brake.

5. How detailed should the cut-list be?
List every cut from a 6 m stock length: item number, quantity, cut length, mitre angle (0°/45°), part ID, and an optimized nesting layout to minimize waste.

6. What tolerances should I apply?
--
7. Which bolts and rivets must be used?
Galvanised 8.8 bolts: M8 × 20 and M8 × 40 with large washers. Steel blind rivets Ø 4.8 mm. List them clearly in the BOM. (chatgpt generated that im not sure if its must have or we can replace that)

8. Does the assembly manual have to be 3D?
Line-art (IKEA style) in an A4 PDF is sufficient: frame welding, bolting sequence, lid installation, chemical anchoring.

9. How many revision rounds are included?
One round of revisions is included, covering technical corrections only—no new concepts.

10. What lock system do you prefer?
A Euro-profile cylinder lock with a two-point latch is ideal. Please pick a model readily available in Poland.

11. Should water drainage be shown?
Yes. Provide drain holes at the lowest ribs of the cladding and specify sealant locations.