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Old 02-26-2015, 09:36 AM   #1
Scott in Missouri OP
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Joined: Feb 2008
Oddometer: 103
Sidecar build: School shop project


Background:
I built this rig and thought I would share the pics- Don’t expect much writing. I waited until I was finished with the major build and will just post all the pics now in order. I did not want to do it each day or week because there are so many thread high-jackers out there that build threads become hard to read. This way, you can just read the build in a few pages. You are all of course welcome to have a ball on this page/forum now and discuss to your heart’s content.

I will say up front- Please do not expect me to reply or monitor the page. I want to encourage folks to build their perfect machine, but I am not really going to have time to answer any questions so you will have to figure it out on your own or with the “expert” guys on the forum. I am sure you will get a lot of opinions.

A Special Thank you to:
Claude at Freedom Sidecar is a Rock Star- Period.
http://freedomsidecars.com/

Alex Neuman and Heath Neuman are great guys and were a great help on this project…mostly because they think I will crash in it.

Kevin Brooks is an old BMW and sidecar buddy (Not that he is old, but the BMWs he works on are old…well actually now that I think of it, he is old too). It is always nice to have a pal I could call to run ideas by and ensure I was on track. He agreed I was and said I should build one.

Kevin and his young Trophy Wife, Barbara still build, ride/tour and race these old BMWs at the Bonneville Salt Flats and all over the west coast.
http://www.brooksmotorworks.com/

The goal:
1-Under $4000. I was sitting in the Middle East for about a year thinking about having a sidecar rig and found the cheapest one out there would be about $4000. I decided to build a complete rig (to include the bike purchase) for under $4000.
2-Had to be vintage and cool. I had a 2006 Ural that I liked so I wanted something similar…but dependable. I guess it didn’t really need to be all that dependable either since there’s a Harley dealer every 37 miles on the highways.
3-I had to be able to sleep in the sidecar tub. I ride around the country and wanted to be able to quickly remove the seat and gear and sleep inside the car when caught in heavy rain.

This build took about two months of working at night and weekends to finish it into a complete machine. It is not totally finished, but I ride it so much now that it will probably be like this for a long time so…here are the pics.

Scott

Triumph Bobber:
http://www.jockeyjournal.com/forum/showthread.php?t=93515
Old BMW:
http://www.jockeyjournal.com/forum/showthread.php?t=95317
Adventure Bike Build:
http://www.stromtrooper.com/dl650-dl650a-2004-2011/81702-vstrom-expedition-xtreme-build-pics.html
150 MPH Dirt Bike:
http://www.stromtrooper.com/dl650-dl650a-2004-2011/81702-vstrom-expedition-xtreme-build-pics-4.html
1951 Ford Shop Truck:
http://www.jalopyjournal.com/forum/threads/1951-ford-truck-project-pics.320631/
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Old 02-26-2015, 09:42 AM   #2
Scott in Missouri OP
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The bike as found and rescued.



Ugly and rusty.

Carb was nasty.

Scott in Missouri screwed with this post 02-26-2015 at 10:32 AM Reason: Add comments
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Old 02-26-2015, 09:44 AM   #3
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The Plan















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Old 02-26-2015, 09:47 AM   #4
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Patterns













PLASMA TABLE VIDEO:
http://vid1379.photobucket.com/album...pskko90vn3.mp4






Scott in Missouri screwed with this post 02-27-2015 at 08:29 AM
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Old 02-26-2015, 09:49 AM   #5
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Subframe









REAR MOUNT:
http://vid1379.photobucket.com/album...psjmz9wjff.mp4






Scott in Missouri screwed with this post 03-02-2015 at 07:20 AM
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Old 02-26-2015, 09:52 AM   #6
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Mounts


All this hardware is from Claude. If you are building your own sidecar- Your first call is to Claude at Freedom Sidecar. Please don't call him to design your rig over the phone, but if you are a true do-it-your-selfer, he can help you get the parts you need.
http://freedomsidecars.com/
















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Old 02-26-2015, 09:54 AM   #7
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Frame



Tube Bender Video:
http://vid1379.photobucket.com/album...psxifpibhb.mp4

Tube Nothcher Video:
http://vid1379.photobucket.com/album...psnzyiglm4.mp4

Axle/Lathe Video:
http://vid1379.photobucket.com/album...psutkluoo9.mp4









Video of the Chassis:
http://vid1379.photobucket.com/album...pskbdabvu9.mp4

Scott in Missouri screwed with this post 02-27-2015 at 07:52 AM
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Old 02-26-2015, 09:57 AM   #8
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Frount Subframe









This is how all of the 5 small pieces are now mocked up in place for a perfect fit to the bike...now I can tack weld them on the bike and they will become one solid rear mount- Then put the piece on a table so you can get to all the cracks and tight spots and weld it into one super-strong mount. The two pieces that hold the tube/threaded bung are strong, but when the stress of the sidecar is added it would have flex. The new piece triangulates from the actual engine mount and stops any flex by anchoring it to the small bracket running at a 45 degree angle.

The front mount is 3 pieces that after welding will become a smaller (10% less steel), cleaner (With "H") mount design that is also 1/2" closer to the bike and still has more than enough space from the front exhaust pipe. Now that I have the end of the clevis tube measured 7.5" from the center of the bike, I can weld it the mounts and it will be strong as a boat anchor.

Finally, all the "pieces" become "parts". It is great when the plan comes together, but if you mess it up...it is time to start over.

The design challenge was to make small pieces (easily reproduced on the plasma table) that could be fitted to and welded onto a bike and "then" be removed/installed as a unit. I think at 1/4" the steel is more than thick enough (probably overkill) but for the extra overall weight of 2 pounds I am happy with it. Additionally, I had to remind myself- I am putting an entire sidecar on the bike so what is a heavy mount going to hurt?

The extra arm that joins the upper and lower mounts is really probably overkill, but again I thought that if I overloaded the front strut arm by "flying the chair" the two will be connected and distribute the load. Three of the four mounts are bolted to factory motor mount locations where the frame is strong. The fourth mount will be at the rear shock where the frame is joined to a cast piece which is again super strong.

Once these mounts are welded up I can focus on the sidecar frame and suspension while keeping the tub in the back of my mind.

Scott in Missouri screwed with this post 02-27-2015 at 08:06 AM
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Old 02-26-2015, 09:59 AM   #9
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Frame and Disc Brake










Harley Bagger Air shocks are cheap used and you can adjust them when you have a passenger or cargo for stability. I also have a set for the bike so the entire rig is adjustable.

This pivot bearing assembly worked great and is from Claude at Freedom Sidecar. I just welded the arms to my specifications. Don't build what you can buy.
http://freedomsidecars.com/


Scott in Missouri screwed with this post 02-26-2015 at 11:11 AM
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Old 02-26-2015, 10:04 AM   #10
Scott in Missouri OP
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Sidecar Tub Patterns















ENGLISH WHEEL ARCH VIDEO:
http://vid1379.photobucket.com/album...pstqcgjsor.mp4

ENGLISH WHEEL VIDEO:
http://vid1379.photobucket.com/album...psocmqj0nw.mp4





Scott in Missouri screwed with this post 02-27-2015 at 08:14 AM
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Old 02-26-2015, 10:07 AM   #11
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English Wheel/ Tub Forming











Never used a wheel before but tried this to get some shape on the nose.
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Old 02-26-2015, 10:11 AM   #12
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Metal Work on the Tub



I needed a couple tools.











I remember thinking that I did not want to be doing this somewhere in this phase.
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Old 02-26-2015, 10:12 AM   #13
usgser
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Scott, I'm not qualified to comment on the engineering but the build looks GREAT to me. You've combined two my favorite things: sidecars and Sportsters. Nicely done.
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Old 02-26-2015, 10:15 AM   #14
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Top of the Tub

This was a pain and took a day or so to design and form.

FLOOR VIDEO:
http://vid1379.photobucket.com/album...ps0pb4npnj.mp4

METAL SHAPING VIDEO:
http://vid1379.photobucket.com/album...pssdcmdsy1.mp4










Not too bad of an experience for a first shot at working with sheet metal and a wheel.













Cleco pins are your friend.

Scott in Missouri screwed with this post 02-27-2015 at 08:18 AM
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Old 02-26-2015, 10:17 AM   #15
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Fender





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