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Old 01-15-2011, 08:26 AM   #16
Salsa
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I'm sure your brother knows, but you can laminate multiple sheets of plywood together and get some curvature in it.

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Old 01-15-2011, 07:00 PM   #17
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Refinements...

After discussing the project at length with my brother today, we've decided to take a slightly different approach.

Instead of using the straight-sided version in the drawing I posted, the new design will essentially be a box for the rear two-thirds with a more rounded "nosecone" for the front third.

This should simplify construction and improve the overall lines (I'll post an updated rendering in a day or so).

Basically, after building a simple wooden box we'll glue some shapeable foam to the front of the box then use a rasp and sandpaper to shape the "nose" to the desired contours.

Similarly, we'll glue more of the foam to the top and rear of the box/body to create the arched top and to make rounded corners at the rear.

Then the box/body and foam parts will be fiberglassed together to create a single body.

I hope all that makes sense. The rendering should make it more clear.

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Old 01-16-2011, 06:30 AM   #18
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Something like this:

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Old 01-16-2011, 11:51 AM   #19
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Very cool. Thanks for keeping us in the loop on the process...I'm very curious to see how it turns out and how the dogs like it...
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Old 01-16-2011, 01:32 PM   #20
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Looking good. Would love to have a hack and a lab. What about hearing protection for them?
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Old 01-16-2011, 01:48 PM   #21
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Another tack...

I went by my brother's this afternoon with Bailey in the hack to discuss the project and he tells me he's got an entirely new approach...

"I was sitting there looking at these pieces of foam last night and started trimming them on the on the band saw," he tells me, then brings these pieces out of his shop and arrayed them on the driveway.

Turns out he had enough foam to make a mold for the entire sidecar body (after they're glued together and more shaping is done of course). Once the mold is done, it's just a matter of laying up the fiberglass, cutting a hole out for the cockpit, painting and trimming.

For once I'd left my camera in the tank bag on another bike, so had to make this one with my piss-poor camera on my cell phone, but I think it shows the concept:



He didn't have any glue today so we couldn't do any more. Will be hopefully doing the gluing up the mold next Friday or Saturday and by then my epoxy resin and fiberglass cloth will be in. And maybe the weather will be decent for beginning the fiberglassing.

By shaping with a rasp and sanding this method will give many more options for the body shape than the wooden-frame method we'd earlier planned to do.

I'll update here when more progress is made.
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Old 01-21-2011, 01:26 PM   #22
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nice work!

And great pics o' the dogs too. I'm sure they will appreciate all your work too!
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Old 01-21-2011, 01:46 PM   #23
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Thanks!

Quote:
Originally Posted by The Rev View Post
And great pics o' the dogs too. I'm sure they will appreciate all your work too!
Here's another (en route to Bailey's first camping trip this week)...

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Old 01-21-2011, 02:28 PM   #24
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Another...
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Old 01-21-2011, 07:32 PM   #25
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Bailey's jacket is looking a bit plain. When is she gonna get patched in?


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Old 01-21-2011, 10:49 PM   #26
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Actually, I was toying with the notion...

Quote:
Originally Posted by See-Double-You View Post
Bailey's jacket is looking a bit plain. When is he gonna get patched in?


...of having a patch made for the backs of both Bailey's and Roscoe's leather jackets. Roscoe is bigger and has a brown leather jacket from the 1950s my brother gave him.

It was also my brother who suggested the insignia for the patch:

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Old 01-22-2011, 12:43 PM   #27
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Quote:
Originally Posted by GSBS View Post
Here's another (en route to Bailey's first camping trip this week)...

What a sour puss! You must hurry and finish this project so he'll have his buddy with him.
Glad to see it taking shape and coming along so quickly
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Old 01-22-2011, 03:21 PM   #28
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Today...

...and a 12-pack of Millers later:

Cutting the foam for mold:


Several of the 20 total pieces:


Beginning the gluing up process:


Checking the cuts on the rear end section:


Making it whole:


Duct tape to hold pieces together until the glue cures:


In my pickup to take back to the house for sculpting:
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Old 01-23-2011, 12:51 PM   #29
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Looks great. Are you going to lay it up in two sections so you can remove the foam (and have more space? Or is the foam a structural component?
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Old 01-23-2011, 02:00 PM   #30
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chopper...

Quote:
Originally Posted by Qwik View Post
Looks great. Are you going to lay it up in two sections so you can remove the foam (and have more space? Or is the foam a structural component?
I'm going to check next week what it would cost to have it shot with a chopper gun - all in one piece - then cut out for the cockpit and then lay up a single layer of cloth over the whole thing. If shooting with the chopper is too much $$$, then I'll just lay it up by hand.

The foam is just for the shape. Will be gouged out and finally melted with a solvent to remove. I'm thinking I'll roll some pickup truck bedliner for the interior.

As always, any or all of the above plans can change.

Stay tuned.
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