And so it begins....

Discussion in 'Hacks' started by cwadej, Nov 16, 2011.

  1. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    I've been wanting another sidecar since my wife sold hers. A bit more utilitarian than her Terreplane though.
    So I hunted, and I found a Velorex 562 from another inmate for my KLR.
    It arrived today
    [​IMG]

    Not being the patient type, I unwrapped everything to see what I had
    [​IMG]

    My daughter can't wait to take it for a spin
    [​IMG]

    The recipient waiting patiently
    [​IMG]

    I sanded down the sub-frame and put a new coat of satin black on the parts
    [​IMG]

    Tomorrow I'll take the tub off the frame.
    #1
  2. hahnda

    hahnda Been here awhile

    Joined:
    Dec 20, 2007
    Oddometer:
    146
    Location:
    Cameron, WI
    Glad to see it made it there in one piece.

    I'm a little worried about that front upper mount though?
    #2
  3. DirtDabber

    DirtDabber cultural illiterate

    Joined:
    Jul 10, 2007
    Oddometer:
    8,393
    Location:
    Way, Way North GA
    In for the build on this one. :clap
    #3
  4. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    How so? I emailed Jay at DMC asking if it would work with the IMS tank, he said yes. I didnt tell him it was a non-vented tank. Hmmm? May take some playing. I'd hate to go back to the stock tank :( Hopefully he'll chime in here with his expert opinion.
    #4
  5. hahnda

    hahnda Been here awhile

    Joined:
    Dec 20, 2007
    Oddometer:
    146
    Location:
    Cameron, WI
    It might be possible. I'm not exactly sure?

    These pics might give a better idea.

    [​IMG]
    [​IMG]
    #5
  6. Ivan Rider

    Ivan Rider Been here awhile

    Joined:
    Feb 19, 2008
    Oddometer:
    628
    Location:
    Bodega Bay & Galt. California
    I tried to put an IMS tank just like that on my KLR rig with Dauntless mounts and it would not work. Sold the tank.

    Attached Files:

    #6
  7. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    I guess I'll have to put the stock tank back on. Sure will miss the 300 mile range though.
    #7
  8. Heyload

    Heyload Remastered Classic

    Joined:
    Dec 14, 2009
    Oddometer:
    8,790
    Location:
    San Antonio
    In! I want to see this. I will even refrain from my customary KLR jokes.
    #8
  9. MotoJ

    MotoJ Mobtown Hacker

    Joined:
    Apr 14, 2011
    Oddometer:
    1,186
    Location:
    Baltimore
    Please indulge us all with lots more subframe and attachment pics, if you have the time!
    #9
  10. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    I had to take a couple days off to hang out with the kids. I'm just glad they still want to.
    I continued today, starting with the subframe. I took off my beloved IMS tank and decided i should put stronger bolts on the bikes subframe, so I did the drill through method and replace the junk with 12.9 bolts. Much better for the side car use.
    I loose assembled the DMC subframe to the bike.
    [​IMG]
    [​IMG]
    [​IMG]

    All tightened up.
    [​IMG]

    Now time to tear the tub off the frame.
    [​IMG]

    And examine the frame.
    [​IMG]

    Inside the tub. This hack is already paying off!
    [​IMG]

    Finally take the fender apart.
    [​IMG]

    That's the day for me. Took longer to drill through the frame for the new bolt than I tought it would.
    #10
  11. BeeMaa

    BeeMaa Hack Pilot

    Joined:
    Feb 13, 2011
    Oddometer:
    1,098
    Location:
    NoVA
    Hope your dog isn't looking for a tire to water.
    #11
  12. eldomike

    eldomike Who Cares

    Joined:
    Aug 6, 2009
    Oddometer:
    958
    Location:
    Southern Illinois
    Looks like a nicely redone frame and spindle...have fun!
    #12
  13. toastmuncher

    toastmuncher I be new round here! Ello

    Joined:
    Jan 3, 2009
    Oddometer:
    678
    Location:
    Chepstow, South Wales, UK
    so, the bike going red or the tub going, erm, sandy colour?
    #13
  14. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    It's been a while since I got to work on it. Dead bearings, blown shock, and of course family stuff.

    I got new bearings for the swingarm. I figured wider would be better, right? So instead of 12mm that were in it, I went with 17.5mm. Double ball bearings. Sealed of course.

    I got the frame all back together, and mounted on the bike. 3/4" leanout, 1" toe in. (the board was so I could set my level on it)
    [​IMG]

    I knew I didnt want to stay red with the body, so I went tan to match the bike, with a roll on bed liner lower half. That stuff is a pain in the butt! I did have to replace my IMS tank with the stock one, but no biggie.
    [​IMG]

    That was warming up for a test ride down the street. Felt good and solid. Tracks straight when I put in nuetral and let off bars, so I'm happy!

    I still need to replace the shock. I'm going to try one off a 1993 GS500, which just arrived as I was typing this. We'll see how it goes.

    I'm still waiting on the lights to arrive to mount on the fender, which will be painted to match the tub. More to come....
    #14
  15. Pugsley/Hobbfather

    Pugsley/Hobbfather Been here awhile

    Joined:
    May 8, 2008
    Oddometer:
    415
    Location:
    Barnard, VT
    Inspiration for if I ever stop commuting on mine long enough to 'prepare for winter' here in VT. Since I will have to build my own frame, what track width did you wind up with using a 'real' sidecar frame?
    Thanks for sharing!
    #15
  16. ricmachado

    ricmachado Been here awhile

    Joined:
    Jul 15, 2010
    Oddometer:
    303
    Location:
    Canyon, TX
    cannot believe just saw this thread today...

    nice looking bike and hack, keep the pictures coming and we can exchange info since I'm also working on the same setup :D

    I'll send some pictures of mi subframe, if you still have the tank, maybe it will work on mine and we can make a deal.
    #16
  17. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    I've still got the fender, lights and seat to finish, so more pics and progress to come. Also with my utility box installed for solo camping trips.

    Sorry, but I sold the IMS tank to a friend.
    #17
  18. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    It's right at 48 wide.
    #18
  19. BeeMaa

    BeeMaa Hack Pilot

    Joined:
    Feb 13, 2011
    Oddometer:
    1,098
    Location:
    NoVA
    It is really coming along nicely.
    Like the paint.
    Keep us posted on further work.
    #19
  20. cwadej

    cwadej Keeper of the truth

    Joined:
    May 20, 2008
    Oddometer:
    936
    Location:
    Arlington, TX
    It's been a while, with a bit of sorting out.

    Since we last saw it, I've added a seat from Nothern tool which hinges in the front for access to the trunk. Cut the windshield down to 7" and painted black. I put a board under the body for support, as the ballast was starting to crack the fiberglass in the trunk. I'm sure it's due to being abused off road, but now all is good. The board also gives me a mounting platformfor a utlilty box should I want to put it on. Takes about 15 minutes to swap out. I plugged several holes in the car body, leaving one for drainage. I found the hard way that the car body filled much faster than it would drain when riding in a river.

    Still to come will be a cover, and probably fabric side panel "doors"

    [​IMG]
    #20