Yamaha FZ1 dual sport sidecar build - Page 2

IsAnOzzie · 05-21-2011, 08:47 PM

Quote:

Originally Posted by 3legs

OMG. Wow nice bike. I don't know what it's like in the states but we don't have a lot of female sidecar riders here in Australia but those that do, earn a hell of a lot of respect from us blokes. More power to them I reckon. Sorry she isn't your missus any more but anyway I digress, MORE PHOTO'S please

3legs

I met a lady recently (a fellow club member) who has a Ural rig, I have worked on it a little for her and she is now riding a lot more. On the sunny Central coast NSW.

HogWild · 05-21-2011, 08:50 PM

Nice wheel!

Go get'em Neptune!

SikDMAX · 05-21-2011, 09:52 PM

Awesome!

Following for sure. Would like to build a sidecar'd rig one day for my dad whos in a wheelchair.

Brendan J · 05-21-2011, 11:46 PM

Thanks for that Neptune looking at doing something simiular on my hack build.

Neptune03 · 05-22-2011, 04:09 AM

The calipers are mounted so they are floating. The bearing is clamped by a split collar that I welded a small bracket to. Then I cut out the larger bracket that the caliper bolts onto. You can see the three bolts that attach it to the split collar and its bracket. The brackets were cut out of 1/4" metal plate using a hand held angle grinder. The tolerances between the wheel and caliper are very close and the two sides had to be identical. I wish there was a way to have kept track of all the hours I spent grinding metal.

If you look closely you can see how the width of the front tire was accommodated. I machined a short section of tube at both ends that then fit into the upper and lower triple clamps. The actual down tubes were temporarily held in place to the short tube in the triple clamps with two split collars welded together. The down tubes are forward and rotated outwards from the tubes in the triple clamp to achieve the needed width.

The down tubes are double wall. I slid one tube inside the other before bending them to meet the swing arm's mounting brackets / pivot point. I have seen pictures of leading link forks broken below the triple clamp so the double wall should hopefully eliminate that.

Motorfiets · 05-22-2011, 07:19 AM

Quote:

Originally Posted by Neptune03

respect!

D.Bachtel · 05-22-2011, 10:14 AM

I do like your fabrication skills, outstanding!
The front swingarm double walled and fitted up with machined ends is real clean. Good thoughts there, lots of contemplation I'm sure.
Fitting the hub/spokes to a new rim..... that takes skill and some nice equipment. Super welder you got there.

Still anxious to see the final product.

Come on.. just one shot from the rear, consider it a teaser.

Don in Nipomo

ClearwaterBMW · 05-22-2011, 11:06 AM

as was already mentioned above.... THIS picture:

MUST be on the front page of some magazine
i'm really not sure which one
but...
you've really touched a lot of folks with this one
thanks for posting it

in fact, i've spiced that picture up a bit, too
hope you don't mind me posting it (i'll remove it, if you do)

Neptune03 · 05-22-2011, 09:52 PM

Quote:

Originally Posted by D.Bachtel

I do like your fabrication skills, outstanding!
The front swingarm double walled and fitted up with machined ends is real clean. Good thoughts there, lots of contemplation I'm sure.
Fitting the hub/spokes to a new rim..... that takes skill and some nice equipment. Super welder you got there.

Still anxious to see the final product.

Come on.. just one shot from the rear, consider it a teaser.

Don in Nipomo

Hey Don, here is the teaser shot from the rear you were requesting. I can't say I understand why you were so anxious for it

Neptune03 · 05-23-2011, 06:28 AM

Thought I should mention, in the previous pictures of the front end, it looks like I used rod end ball joints at the bottom of the leading link down tubes (the pivot point of the swingarm). That would have been an easy choice but Bill suggested that if rod end ball joints were used they would allow movement that was not desired, especially as they became worn. Because I wanted the ability to adjust the pivot point vertically I started with a 3/4" rod end but removed the ball and welded in some parts I machined so I could insert nylon bushings and a brass sleeve (the brass sleeve that goes into the bushings is not shown in the picture). I should have taken an after picture, but I hope you get the idea.

Only caught myself on fire once while welding because I got smart and picked up a cheap long sleeve welding jacket.

I picked up a VFR single sided swingarm on EBay for a reasonable price. In one easy step I had, a nice looking strong swingarm, shock, brake rotor and caliper. The 15 x 5.5 car wheel was purchased from Wheels Next and to provide clearance for the wheel and 175/70/15 rally tire I found an aluminum spacer online that only needed minor modification to mount to the four bolt pattern of the VFR swingarm.

D.Bachtel · 05-23-2011, 08:58 AM

Quote:

Originally Posted by Neptune03

Hey Don, here is the teaser shot from the rear you were requesting. I can't say I understand why you were so anxious for it

Yeah! Baby's got back, you could set a cool one on that.
Subframe (yours not hers) looks superb.

Don in Nipomo

Neptune03 · 05-24-2011, 07:17 AM

It's starting to look like a sidecar outfit but still a LONG way to go.

I would like to have been able to mount a couple of RotoPax gas cans or some kind of storage back there but that darn wheelchair has to go everywhere I do.

HogWild · 05-24-2011, 07:28 AM

WOW, very nice!

ClearwaterBMW · 05-24-2011, 07:45 AM

Wow from ME, too

larryboy · 05-24-2011, 08:40 AM

Super nice work!!

05-21-2011, 08:50 PM	#17
HogWild Scott Whitney Joined: Nov 2003 Location: SoCal USA Oddometer: 2,225	Nice wheel! Go get'em Neptune! __________________ Going where no Harley has gone before HogWildRacing.com

05-21-2011, 09:52 PM	#18
SikDMAX Studly Adventurer Joined: May 2010 Location: San Luis Obispo - 58 229 & 1 Oddometer: 687	Awesome! Following for sure. Would like to build a sidecar'd rig one day for my dad whos in a wheelchair. __________________ Matt - SikMoto www.Facebook.com/SikMoto San Luis Obispo, CA

05-21-2011, 11:46 PM	#19
Brendan J ONE HACK AT A TIME Joined: Feb 2008 Location: ROLLIN AROUND THE VICTORIAN COUNTRY SIDE !!! Oddometer: 1,396	Thanks for that Neptune looking at doing something simiular on my hack build. __________________ 01 HONDA VFR800 13 HUSQVARNA WR125

05-22-2011, 04:09 AM	#20
Neptune03 ^OP Adventurer Joined: Sep 2009 Location: Tallahassee, Florida Oddometer: 70	Yamaha FZ1 dual sport sidecar build The calipers are mounted so they are floating. The bearing is clamped by a split collar that I welded a small bracket to. Then I cut out the larger bracket that the caliper bolts onto. You can see the three bolts that attach it to the split collar and its bracket. The brackets were cut out of 1/4" metal plate using a hand held angle grinder. The tolerances between the wheel and caliper are very close and the two sides had to be identical. I wish there was a way to have kept track of all the hours I spent grinding metal. If you look closely you can see how the width of the front tire was accommodated. I machined a short section of tube at both ends that then fit into the upper and lower triple clamps. The actual down tubes were temporarily held in place to the short tube in the triple clamps with two split collars welded together. The down tubes are forward and rotated outwards from the tubes in the triple clamp to achieve the needed width. The down tubes are double wall. I slid one tube inside the other before bending them to meet the swing arm's mounting brackets / pivot point. I have seen pictures of leading link forks broken below the triple clamp so the double wall should hopefully eliminate that.

05-22-2011, 11:06 AM	#23
ClearwaterBMW The Examiner Joined: Jul 2005 Location: Clearwater, FL USA Oddometer: 4,744	as was already mentioned above.... THIS picture: MUST be on the front page of some magazine i'm really not sure which one but... you've really touched a lot of folks with this one thanks for posting it in fact, i've spiced that picture up a bit, too hope you don't mind me posting it (i'll remove it, if you do) __________________ Greg '07 K1200 GT '11 R1200 GS Adventure with a DMC M72DX Sidecar live life like you mean it... but take your family and friends (and DOGS) along for the "ride"

05-22-2011, 10:14 AM	#22
D.Bachtel Gnarly Adventurer Joined: May 2009 Location: Nipomo ,,,, Where HWY 101 and HWY 166 collide! Oddometer: 370	I do like your fabrication skills, outstanding! The front swingarm double walled and fitted up with machined ends is real clean. Good thoughts there, lots of contemplation I'm sure. Fitting the hub/spokes to a new rim..... that takes skill and some nice equipment. Super welder you got there. Still anxious to see the final product. Come on.. just one shot from the rear, consider it a teaser. Don in Nipomo

05-23-2011, 06:28 AM	#25
Neptune03 ^OP Adventurer Joined: Sep 2009 Location: Tallahassee, Florida Oddometer: 70	Yamaha FZ1 dual sport sidecar build Thought I should mention, in the previous pictures of the front end, it looks like I used rod end ball joints at the bottom of the leading link down tubes (the pivot point of the swingarm). That would have been an easy choice but Bill suggested that if rod end ball joints were used they would allow movement that was not desired, especially as they became worn. Because I wanted the ability to adjust the pivot point vertically I started with a 3/4" rod end but removed the ball and welded in some parts I machined so I could insert nylon bushings and a brass sleeve (the brass sleeve that goes into the bushings is not shown in the picture). I should have taken an after picture, but I hope you get the idea. Only caught myself on fire once while welding because I got smart and picked up a cheap long sleeve welding jacket. I picked up a VFR single sided swingarm on EBay for a reasonable price. In one easy step I had, a nice looking strong swingarm, shock, brake rotor and caliper. The 15 x 5.5 car wheel was purchased from Wheels Next and to provide clearance for the wheel and 175/70/15 rally tire I found an aluminum spacer online that only needed minor modification to mount to the four bolt pattern of the VFR swingarm.

05-24-2011, 07:17 AM	#27
Neptune03 ^OP Adventurer Joined: Sep 2009 Location: Tallahassee, Florida Oddometer: 70	Yamaha FZ1 dual sport sidecar build It's starting to look like a sidecar outfit but still a LONG way to go. I would like to have been able to mount a couple of RotoPax gas cans or some kind of storage back there but that darn wheelchair has to go everywhere I do.

05-24-2011, 07:28 AM	#28
HogWild Scott Whitney Joined: Nov 2003 Location: SoCal USA Oddometer: 2,225	WOW, very nice! __________________ Going where no Harley has gone before HogWildRacing.com

05-24-2011, 07:45 AM	#29
ClearwaterBMW The Examiner Joined: Jul 2005 Location: Clearwater, FL USA Oddometer: 4,744	Wow from ME, too __________________ Greg '07 K1200 GT '11 R1200 GS Adventure with a DMC M72DX Sidecar live life like you mean it... but take your family and friends (and DOGS) along for the "ride"

05-24-2011, 08:40 AM	#30
larryboy Paint it black. Joined: Jan 2005 Location: Über Alles,Ca Oddometer: 12,863	Super nice work!!

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