How I made a hauler for my GS500 for a Jeep Grand Cherokee/SUV (not a trailer)

[lilwoody]

You're going need access to a large drill press, drill bits up to 1", a cut off saw or steel band saw would be very helpful too. I wouldn't put this on anything smaller than a Jeep Grand Cherokee, mine is full time 4 wheel drive. A roof rack is a must too. A pick up would work, just strap it to the tailgate.

I decided to make a bike hauler that attached to my Jeeps trailer hitch last summer. I saw a motor home carrying a Goldwing on the back and I envisioned something similar for the Jeep and my GS. Here's how it's built.
Parts list:
1-4"x1'4"x76" galvanized steel channel
1-5/16x2"x2"x24" box tube
2-2"x24" galvanized unistrut
2-2"x28" galvanized unistrut
4-5/8"x3" carriage bolts
1-5/8"x24" all thread
8-5/8 nuts
4-5/8 fender washers
4-regular 5/8" washers
8-5/8 lock washers
2-1"x4" bolts
2-1" nuts
2-1" lock washers
1-5/16x2" eye bolt
2-5/16 nuts
2 5/16 washers
1-5/16 lock washer
1-3/4x6"x30" piece of plywood
I started with a piece of 4"x1/4" galvanized steel out of the bone yard here at my plant. It just so happened to be the exact right length at 60". Then I purchased a 24" piece of box tube to go in the receiver. There was already a hole in the center of the channel so I drilled the second 1" hole near the edge of the channel then through the box tube. Had I purchased the channel I would have put the holes for the bolts near the edge centered in the channel. the holes in the box tube will be important as these holes will mean how far the bike will be from the back of the vehicle. I put the bike as close to the jeep as I could and then using a straight edge from the receiver to the ground I measured from the straight edge to the center of the bike. I then put the channel on the ground behind the Jeep, put the bike on the channel and measured again making certain that the bars will clear anything on the Jeep while loading. Then I put the box tube in the receiver and measured to the first hole and marked it with a center punch. while it was in I marked the receiver pin with the punch.
I drilled the receiver hole first, then drilled the first 1" hole in the box tube on the drill press (I drilled a pilot hole with the bit for the receiver pin hole first then the 1") . I then put one of the bolts through the channel and box tube and used the channel as a stencil for the second hole checking square many times before I hit it with the punch and drilled the pilot hole, then the 1" hole. After I got the channel where it was going to be I drilled the hole for the eye bolt in the center of the box tube 2" off the outside edge of the channel.
Then it was time for the uprights, this was really easy I just drilled a 5/8" hole 1" off the end in the center of the up turned portion of the channel. Then just drew the carriage bolts into the holes with several washers as spacers facing away from the channel. Now cut the all thread for the top of the unistrut in half (12").
I then put the channel on the box tube with the 1" bolts with the lock washers on the under side. Then put the uprights on, I put the front tire on drivers side and tighten that side up very well then put the all thread in the top and snug it up with a fender washer a nut then a lock washer and a nut (this is just the way I chose to do it, you can probably get by with just one nut and the lock washer against the fender washer). Then put the other side on and get it tight enough that the strut will move with some effort, this will be the ramp side.
How to load the bike.
Pull the ramp out to a 45 degree angle to the hauler, slide the plywood in it and push it down until plywood is on the ground. Pull the bike around and line it up straight with the ramp and the channel. get off and run the bike up the ramp feathering the clutch and front break, when the front tire is snug in the front up right you can shut down, it will stand on it's own now. Pull the plywood out of the back ramp and bring the back up rights/ramp guides up onto the back tire. You may need to cajole them around the fender but it fits. Now put in the piece of all thread and lock it down like the front but tighten it and the front up. I attach a ratchet strap to the next hole down from the top of the upright unistrut and attach it to the eye bolt and tighten those up. I then attach a ratchet strap to the same hole on the inside and run it front to rear through the front faring and tighten it up.
Now comes the part where you need a roof rack. I run one ratchet strap from the center of the handle bars to the roof rack then from my back rack (grab bar) to the roof rack and tighten these. Before you button them completely up put some padding between the handle grip and the rear window. I run one last strap from the mid frame to the front roof rack cross member for a little extra support. I them put one last strap around the middle of the bike from edge of channel to edge of channel and over the seat.
I had originally planned to weld in 2, 2" receiver pieces on either side of the trailer hitch. then add 2  more pieces of 2" box tube that would mate up with the extra receivers. It really isn't necessary for a bike as small as the GS. This was the way the Goldwings carrier was made that I got the idea from but a GW is 2.5 times the weight a GS is. 
I drove on a trial run of 400 miles then 2200 miles with this set up at speeds up to 85 mph on the interstate and in some pretty steep twisty roads and on some gravel roads in the mountains without a problem. So bashers bring it on, this thing works.

The 2 -1" bolts that mount the channel to the bow tube and the eye bolt for to 2 outside ratchet straps. If the hole wasn't already in the middle I would have put them on either side.

The front upright unistrut carrage bolt. (inside and outside) nut, fender washer and lock washer. Tighten these up tight and at the proper angle to accept the fromt tire when loadint, this will be the support for the bike while you get the back upright up.

Top of the rear tire/ramp upright with all thread and nuts on. Just tighten up the front and back after the bike is loaded, then put the straps, lights and tag on and head out.

Ramp down ready for the bike.

Hauler on my Jeep.

Bike on the Jeep in NC.

Folded up ready to store.
You are pretty smart people on here I think you can figure out lights and a tag holder. I used jut regular magnetic lights and straped them on with bunjees. I may do something more permenant later but they work for now.

[cboling]

I really like this. How well did the truck handle with the bike strapped on? Did you have any problems from local law or highway law? Does the bike sit against the back gate?

I had thought about this a while back but abandoned it because I didn't have a bike. Now I do, so that would work out nicely.

CB

[scottpA_GS]

Great write up!

Thanks 

[Roadstergal]

Now that's some good ol' fashioned industry!

I used good ol' fashioned cheapskateary and bought a hauler.  It's made for dirtbikes, but that's CYA legality; it's carried the GS just fine.  We've also thrown the Titter on it when the van was full of other bikes.  I really like the hitch hauler concept in general - why go through the hassle of a trailer for just one bike?

GM does trucks better than cars, and the van is no exception; one of the nice features is that the brake lights/turn signals are mounted high, so you can see 'em over a bike on a hitch rack, and don't have to bother with auxiliary lights.  I don't like to surprise people behind me when I'm loaded down.

[lilwoody]

I've hauled it 2600 miles through 4 states so far with no problems. I do have tail, tag and break lights on it. Plus when I use it I put the tag to the Jeep on the holder. I really don't see how it could be a problem. I see folks use those cooler haulers all the time with their tag completly covered and I have yet to see one of them pulled over. I will put air shocks on the back of the Jeep it was a little light in the front but with the full time 4x4 it wasn't a problem at all. We even got 15 plus mpg out of the V8 Jeep with it on.
The handle bar grip on the right side rests a few mms off the back glass. I have a pad I made out of the bottom of a gatorade bottle with some foam rubber in it that I bunjee to the grip.