Author Topic: Sidecar build  (Read 34572 times)

Offline Powder Keg

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Sidecar build
« on: November 17, 2008, 08:28:23 PM »
I bought a 1984 GL1200 a few months ago and have had a blast with it. I was chating with my wife one evening and mentioned that I thought a sidecar would be fun to try. She got all excited about the idea. Shortly after, I started designing and building one. Here are a few pictures. I'll post more soon.

The springs are salvaged off of an old Snowmobile.


One of the frame mounts I built.


Here is the axle I'm working on.


I bored out a Goldwing wheel to accept Timken bearings.


I laminated the floor out of 3/16" plywood.


Here I'm trying to get it all clamped together. My buddy Lee is helping me.


I got a good start on the body.


Hope you like it so far....

Wes
« Last Edit: November 17, 2008, 08:31:09 PM by Powder Keg »
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

Offline Brass_Machine

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Re: Sidecar build
« Reply #1 on: November 17, 2008, 08:50:25 PM »
It's looking good so far Wes!  :clap: Good job!

One question... that Goldwing wheel on the lathe. 17in? How big is that chuck???

Eric
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Offline Powder Keg

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Re: Sidecar build
« Reply #2 on: November 17, 2008, 09:04:11 PM »
It's a `16" chuck. I had to do that part at work;o) We have 4 20" X 80" lathes there.  I'll try and get a picture of the mill I run also. It has a 25" X 60" table. It weighs 24000 pounds.

Wes
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

bogstandard

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Re: Sidecar build
« Reply #3 on: November 18, 2008, 01:29:30 AM »
Lovely work as usual Wes, it also must be nice not having to worry about getting big bits machined.

I was wondering how you got on with your wing, enjoying it I hope.

The chappie I bought mine off wanted me to have one of the wing sidecars off him. But after a bit of thought I turned him down.

Travelling in the UK is slightly different than in the US. You use a bike to get thru all the continuous traffic jams, which you can't do when you are dragging a chair. I will have to stick with the trailer, but of course you can't carry an extra passenger in that (not legally anyway).

John

Offline Darren

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Re: Sidecar build
« Reply #4 on: November 18, 2008, 01:44:30 AM »
Looks good Wes, that axle looks a serious bit of kit too..
You will find it a distinct help… if you know and look as if you know what you are doing. (IRS training manual)

Offline CrewCab

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Re: Sidecar build
« Reply #5 on: November 18, 2008, 04:23:32 AM »
Nice work Wes  :thumbup:  Look forward to seeing this progress.

CC

Offline Bernd

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Re: Sidecar build
« Reply #6 on: November 18, 2008, 10:35:43 AM »
Nice work Wes.  :headbang:  :thumbup:

Bernd
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Offline Powder Keg

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Re: Sidecar build
« Reply #7 on: November 19, 2008, 08:06:58 PM »
Thanks for the kind words :mmr:

Bogs, The wing is great!!! I'm still riding it and it's been in the 20's here in the morning :mmr: No traffic jams here though? Rural Idaho. I can't even remember if I've ever even been in a traffic jam? Once in a while a train blocks all the roads across town, Is that what your talking about?

I got a few more pieces of wood cut tonight. I'll try and get a couple more pictures.

Later, Wes
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

Offline Bernd

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Re: Sidecar build
« Reply #8 on: November 20, 2008, 01:45:39 PM »
Rural Idaho!  :bugeye:  I didn't know they had trains up there.  ;D.

So you're riding in the cold. Got any snow yet?

Bernd
Route of the Black Diamonds

Offline backyard_cnc

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Re: Sidecar build
« Reply #9 on: November 22, 2008, 01:16:44 AM »
looks good so far. I also ride a GL1200, a minty 1985. Don't think I want a sidecar but I do tow a large teardrop trailer behind it! Check it out.

Gerald

Offline dsquire

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Re: Sidecar build
« Reply #10 on: November 22, 2008, 01:57:17 AM »
Powder Keg

Looks like the start of a nice side car. As a kid living in the country there was an older gentelman that used to come around driving an Indian with a side car always looking for scrap metal. I alway liked when he came as he would always talk to us kids and answer any of our questions and let us sit on his motorcycle. He would never give us a ride as the sidecar was always full of scrap metal. I always thought of it as a beautiful motorcycle. This would have been in the late 1940's.

In my browsing yesterday I came upon another 3 wheeler so will post a link here so you can check it out. Maybe this will be your next build!

http://link.brightcove.com/services/link/bcpid1735797252/bctid1729330625

hope this isn't too for :offtopic:

cheers

Don
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Offline Brass_Machine

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Re: Sidecar build
« Reply #11 on: November 22, 2008, 02:24:27 AM »
...

hope this isn't too for :offtopic:
...

Don

It is the natural flow of conversation. I personally do not feel it is :offtopic: as it concerns a motorcycle, a sidecar and your experience. Now if you had been talking about a parrot who rides a surfboard that you saw on the news last night... that would be :offtopic:

:thumbup:

Eric
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bogstandard

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Re: Sidecar build
« Reply #12 on: November 22, 2008, 03:57:47 AM »
In my younger days in the last century, a lot of us motorcyclists used to swap over to a different form of wheels for the winter. They used to have a heater (of a sorts), and were grossly unstable over 70mph. But they did allow you to carry the kids in comparative comfort (rearranging internal organs was the order of the day on B class roads).

http://en.wikipedia.org/wiki/Image:Reliant_Regal_3-30.jpg

You were allowed to drive one if you had a full motorcycle licence because it weighed under 8 hundredweight (896 lbs) and was classed as a tricycle (bike with a sidecar).

I still see a few knocking about, even though they stopped production a fair few years back.

They were affectionally known as 'Plastic Pigs' because of the fibreglass body.

The all aluminium four cylinder, water cooled inline engines started off as 600cc and over the different ranges finished up at 850cc. The engines were used in a class of motor racing, the Formula 700 (the engine converters in the mid 70's were based in Market Drayton, Shropshire, just down the road from where I used to live, and I had mine tuned there, coupled with a higher ratio back axle, I could cruise at 90 if I felt brave enough). I was pulled over by the fuzz a few times, who couldn't believe that a 'pig' could go that fast, I never let on and blamed it on a tailwind or going downhill, they never noticed the large forwards facing Stromberg carb with a big bellmouth (you could only see part of the engine thru the top hatch, and if you wanted to do a lot of engine work, it was easier to drop the engine onto the floor, and lift the body over the top).
I also worked for a while making 'Mountain Range' fire engines (the smaller ones were based on a special six wheeled 'in house' conversion of the Range Rover, one of those would please Crew Cab), and the same basic engines were used on the portable pumps carried on board, two men could carry them easily, because of the light weight.

Getting away from the post slightly, just reminiscing, as we all do.

John

Offline dsquire

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Re: Sidecar build
« Reply #13 on: November 22, 2008, 04:25:58 AM »
John

As long as we are talking about 3 wheelers we're not too far off track.

If they ever outlaw reminiscing as we all do then they will have a fight on their hands.

Cheers

Don
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'til your good is better,
and your better best

Offline Powder Keg

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Re: Sidecar build
« Reply #14 on: November 23, 2008, 01:02:47 PM »
I'm pretty excieted about this project to;o) I got a couple more pieced glued on. Here is the brace infront of where the seat will be. Lots of angles in those little support pieces.


Here I am fitting a couple more braces to the trunk area. They are just sitting on the clamps for now.


I am going to try and get some more done today.

Wes
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

Offline Powder Keg

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Re: Sidecar build
« Reply #15 on: November 28, 2008, 01:31:27 PM »
I got some new clamps :) at Harbor freifght this holiday weekend. I also have some more pictures to post when I get home. They should be listed elsewhere, but since there pieces for the sidecar, I'll post them here. There is a bunch of machining and a bit of foundry work involved :D

Later, Wes
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

bogstandard

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Re: Sidecar build
« Reply #16 on: November 28, 2008, 01:38:27 PM »
It is looking real good Wes.

Are you fitting a brake on it, coupled to the bike back wheel brake, so you can pull up nice and straight, or just a straight freewheeler?

John

Offline Powder Keg

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Re: Sidecar build
« Reply #17 on: November 28, 2008, 02:22:11 PM »
No brake. But I have been toying with the idea of adding a altrinator and a spare battery. Since starting to ride the battery and the fuel department has been my only two troubles. both will be solved here :) I have a altrinaror off a Honda Civic that a friend donated and a batery box that I bought because it was on sale a while back. This will fit nicely in the trunk I think? I am also planing on adding a spare fuel tank to the unit. this will extend my range :D

Wes
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

bogstandard

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Re: Sidecar build
« Reply #18 on: November 28, 2008, 02:55:19 PM »
Luckily mine was fitted with a souped up alternator and battery just before I bought it. I am just rigging up an outside power point to keep the bike on trickle charge permanently while it isn't being used.

I too am a bit disappointed with the range of the bike, especially if I give it a bit of a burn up. I have had a few sweaty moments trying to reach a filling station. I should really keep a gallon can of fuel in the pannier just in case. I have a new timing disk to fit into the engine that hopefully will give me better MPG and more power, as the engine for this bike was derated by Honda, and this mod brings it up into line with the Valkyrie with regards to ignition timing.

If fitting a battery box in the trunk, I would suggest giving the whole area a coat of acid proof paint, the fumes will attack both metal and wood, you don't want the wife to fall out of the back (unless of course she is well insured).

John

Offline Powder Keg

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Re: Sidecar build
« Reply #19 on: December 01, 2008, 10:35:21 PM »
I've been way to busy to work on this project much, but i have been squeezing it in where I can. At school I made this.

It is the start of a tail light for my sidecar. It is 16" wide by 4" tall by 2.5" deep. I drew it up and programed it at school then machined it :) Here is a another shot at a different angle.

I still have to remove all of the material off of the back side. The thickest section will be .300" around the flange. The rest will be .250". I am going to take the sockets out of a commercial unit to light it up. I might try LED's also? I still haven't decided. It took 1 hour to do the machine work so far, including drilling and tapping all the holes.

Wes
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

Offline Bernd

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Re: Sidecar build
« Reply #20 on: December 02, 2008, 11:25:47 AM »
Looking good Wes. I'd go for the LED's. They are so much brighter.

http://www.trailerpart.com/ check this place for LED lights. Might have something you could use. I put LED's on my trailer that I hauled the mill on. I liked those lights so much I installed LED's on my boat trailer. A bit more expensive but the bulbs last longer.

Bernd
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Offline Powder Keg

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Re: Sidecar build
« Reply #21 on: December 03, 2008, 12:20:11 AM »
Well, I hosed my part... I'll have to try something different. I set the Z tool Height wrong on the first tool and cut my flange mostly off..... :zap:
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

bogstandard

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Re: Sidecar build
« Reply #22 on: December 03, 2008, 02:54:08 AM »
Wes,

Don't get disheartened, even us manual metal choppers turn the handle the wrong way sometimes.

You can't be perfect all the time, and having setbacks reminds us that we are only human.

John

Offline Powder Keg

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Re: Sidecar build
« Reply #23 on: December 05, 2008, 12:51:03 AM »
Well, I aquired anotherpiece of stock and am back to where I was when I messed up earlier this week. I'll continue on it on Tuesday. I also figured out what my problem was. I entered the wrong depth when I was programing it :zap:

Wes
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...

Offline Powder Keg

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Re: Sidecar build
« Reply #24 on: November 08, 2009, 02:00:32 PM »
Well I haven't died. I just fell off the map for a while. I had way too many irons in the fire and had to take a step back. I've been working on my sidecar every chance I get. Sorry I haven't posted any progress I'll try to fill things in here.

I have the body pretty much done.



The frame is all welded up. I went to school last fall to brush up on my skills. here is a test run.



I have the two pieces together.



My rider and some fresh paint.



I'll post some more later:o)
Wesley P
A Gismo ??? If it has a flywheel or spins and is made with small parts. I'll take one! If it makes noise, moves, or requires frequent oiling and dusting it's a better deal yet. It's especially right if its shiny and bright; but if it's dirty and dull it wont mater at all...