OK OK lets not put it to bed. I'm a mechanical engineer and was only commenting from my perspective that this looks like a very doable bike fix, even if you buy one. We take our bikes everywhere so this is important to us.
Wayne&Sam, I went to the thread you suggested and it is indeed more informative. I hope to see one soon. I didn't mean to open up a can of worms but Denis is right, PVC with a wood core is more than enough to structually support this kind of weight. I might try to build one. I'll post some pics if I do
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