HOW-TO BUILD A KICKER RAMP

Kicker Ramp Complete

Welcome to the how-to on building a bike kicker ramp, for less than $40. I'll provide a list of tools & parts needed to fabricate a custom portable kicker (~25 lbs) that you can take wherever you go. It takes about 2 hours to build.

1st things first, you'll need the following equipment:

  • Drill w/ the following bits:
    • #2 phillips-head bit
    • 6/32" drill bit
  • Circular Saw
  • Zig Saw
  • Right-angle triangle
  • Table measure
  • Hammer

*** This page is print friendly ***

Kicker Ramp Base

...then go to your local hardware store and pick up the following bits and pieces:

  • (1) 2' x 4' 3/4" plywood (sides)
  • (1) 2' x 4' 1/4" birch plywood (surface). I found the ACX-type was too rigid and may crack.
  • (2) 1" x 4" x 8' treated boards (cross braces)
  • 1 lb of 1 5/8" #6 coarse screws
  • (3) #6/32" 3/4" machine screws (will be used to sandwich 2 pieces of the 1/4" ~4" section of plywood together)
  • (3) #6/32" pronged t-nuts (for the 3 machine screws)
  • 1" panel board nails [brad head w/ ring shank] (used to nail top edge and sandwich)
  • (1) 2" x 4" x 4' treated board
  • Wood glue
  • (1) 1/2" x 4' PVC pipe or "flexible" material. This is for drawing the arc.

Sides Arc Cut Measurements (length x height):

(starting from start of ramp [ground])

  1. 0" x 1/2" [start]
  2. 3 1/8" x 1"
  3. 12" x 3 1/2"
  4. 16" x 4 1/2"
  5. 19 3/4" x 6"
  6. 24" x 8"
  7. 28" x 10"
  8. 32" x 12"
  9. 36" x 15"
  10. 40" x 18" [end/top]
  • You will make a straight cut from #10 (40" x 18") to the base 48" point.

Instructions

Cuts (all but one)

  1. Cut the (2) 1" x 4" x 8' into (8) 22 1/4" boards. These are the cross members.
  2. Cut the 2" x 4" x 4' into (2) 22 1/4" boards. These are also cross members.
  3. Using the 2' x 4' 3/4" plywood [1st side] & using the Side Arc Measurements table (left side) create the arc.
    1. Draw a straight line from the 40" x 18" mark to the point of the base of the 4' piece (look at the picture for reference)
    2. *** Important - the arc only goes to the 40" mark in order to prevent the ramp from flipping when you jump ***
  4. Temporarily mount a screw at each mark in step #3 (just opposite of the line). This will be used to hold the flexible pipe or piece of wood while flexing it to draw the arc.
  5. Flex the pipe or piece of wood along each of the screws and draw the arc.
  6. Remove the temporary screws from step #4.
  7. Using the Zig saw, cut out the arc & straight line.
    1. *** Important - don't use the circular saw to make the straight cut or you will NOT be able to make the 2nd side ***
  8. Sand any high-spots in the arc.
  9. [2nd side] Using the 1st side, draw the 2nd side (flip & rotate of 1st side).
  10. Using the Zig saw, cut out the arc & straight line.

Assembly

*** Important - the 1" x 4" Cross members must be flush with the plywood arc ***

  1. [Both sides on bottom] At 24" centered, mount the base-middle brace (ground contact [not arc]) 1" x 4" with 2 screws on each side.
    1. I set both sides vertical (far side against a wall) on a table with the base-middle brace in between so I didn't have to figure out how to hold everything together.
  2. [Both sides on arc] At [start] 4.5" mark, draw a line. This is the start edge of the 1st cross member.
    1. Mount cross member with 2 screws on each side.
  3. [Both side on arc] Measure 2 3/4" from edge of mounted board. Mark it. This is the start edge of the next cross member.
  4. Repeat steps #2 & #3 for the remaining (5) 1" x 4" boards.
    1. The last/top board must be flush at the 40"/top edge, so you will have less than 2 3/4" between it and the adjacent board.
  5. Using the 1st 2" x 4" cross member, mount it directly below the last cross member (step #4.1) along straight edge.
  6. Mount the 2nd/last 2" x 4" cross member at the base/bottom and 48" mark.
  7. [surface] Align the 2' x 4' 1/4" birch plywood at the start edge and (slowly) push the center of the plywood down to the arc with your knees.
    1. While holding the board down, (check that the plywood is flush with both sides) mount it using 3 screws/cross member (7 of them = 21 screws).
  8. [Final cut] Cut the excess (~4") off of the 1/4" plywood. You will use this cut piece to "double up" the 1/4" plywood at the start of the ramp.
  9. [sandwich] Put liberal wood glue on 1 side of the cut piece.
  10. [sandwich] Carefully lift the start of the 1/4" plywood enough to slide the piece cut from step #8.
    1. Slide the "glue" side of the cut piece under the 1/4" plywood.
    2. Using the "panel" nails, mount the "sandwich" to the sides using 2 nails on each edge.
    3. Drill (3) 6/32" holes for the 3 machine screws and pronged t-nuts.
    4. Fasten the (3) 6/32" machine screws with the pronged t-nuts under the "sandwich" plywood.
  11. Now add your favorite stickers and paint it up! You're done. Get out and enjoy!
Resources

Blake Samson (2018). How To Build A Mountain Bike Mini Kicker | Blake Builds A Portable Wooden Jump. YouTube. Retrieved from https://youtu.be/iBAmmg3MJto

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