Camp F*ck n F*ck rat-rig assembly

Discussion in 'Some Assembly Required' started by MotoJ, Aug 6, 2011.

  1. MotoJ

    MotoJ Mobtown Hacker

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    Back in April I was thiiiis close to buying a brand new 2011 Ural T rig, but the credit union yanked the rug out from under me, right at closing. Seems Ural wasn't in their database, plus I wanted to buy a rig out of state. Long story short, no supervisor would sign off on the final loan paperwork.

    So, plan B- make my own! Somehow I'd gotten the sidecar bug, even though I'd never driven a rig and only been a passenger a handful of times. I did own a suitable hack tug: a beat up 1978 R80/7. A little ragged, but only 14K miles and sound mechanically. I rescued this off a street in South Baltimore, where it had been left by the owner when he left the country without making arrangements for his bike. It was on a downhill slope and had trash up to the cylinder head and two flat tires. A little TLC and it's been my faithful steed for five years.

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    Good enough donor there. Now for the other half... Prior to the Ural deal, I had seen a forlorn Dnepr sidecar of indeterminate age on Craigslist. I initially passed, but told a buddy of mine, Tommy T (more on him later) about it, and he bought it. After the Ural deal fell through, I called him and he passed it on to me...

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    So, the two major components are accounted for. Time to devise a cunning plan....
    #1
  2. Bendernz

    Bendernz Torrential

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    A plan so cunning you could stick a tail on it and call it a weasel.
    #2
  3. panorton

    panorton Charming as F**k

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    It's So Cunning You Could Brush Your Teeth With It.
    #3
  4. MotoJ

    MotoJ Mobtown Hacker

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    I like the cut of your jib, young fella me lad!
    #4
  5. baldwithglasses

    baldwithglasses Godspeed, Robert

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    Hell naw, it's Kennesaw!
    'scribed. now git ta werk, youse!
    #5
  6. MotoJ

    MotoJ Mobtown Hacker

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    I should back up a little and explain that this project has been underway since late April. It was a spur of the moment decision when my Ural deal tanked. I had the bike and a POS car, so why not, right? Like a lot of my projects, it's been poorly thought out, underfunded, and haphazardly executed, but the results have been pretty cool so far, at least to me. I'll work this thread chronologically and bring things up to the present in a series of posts. Luckily I took pictures of most of the process. Poor quality cell phone pics at that! I figured what the hell, I have a lot of photos, throw up a thread...

    So, the sidecar: unknown vintage Dnepr tub and frame, no sidecar wheel drive. From a parts diagram I found on line I think it's an earlier one. Maybe early sixties? Original paint outside, with still hints of pinstriping. Multiple repairs, including what looks like a piece of 70s avacado kitchen appliance panel welded as a patch on the bottom of the trunk. Inside: layers of rust, flourescent orange highway paint, and driveway sealer, topped off with a hearty drenching of cat piss. That became evident when I started stripping it.

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    The original baltic birch or siberian pine footrest was still there. Unfortunately that didn't make it...

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    Miraculously, the original seat and backrest is still there, and the vinyl's not even ripped! I'll clean it with bleach, maybe make a cover at some point.

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    The spare carrier is mounted, and the spin on nut is on the spindle, but no spare. No wheel or shock or brake or even a castle nut, for that matter. Missing rearwards facing light, front is non-original. I began sourcing all this stuff online. When this rig is done it will have parts from all over the US and a few countries in Europe....
    #6
  7. philipbarrett

    philipbarrett Been here awhile

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    I'm hooked - keep it coming...
    #7
  8. MotoJ

    MotoJ Mobtown Hacker

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    This project has been taking place with two sub-projects underway simultaneously. The tub and frame refurbishment has been done by myself on the rear veranda of Chateau MotoJ, while the bike mechanics, fabrications, and generally anything requiring skill and a brain has been performed by Tommy at Camp F*ck'n F*ck,
    his bike shop/rehearsal space/studio/cool hang-out.

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    Starting at Chateau MotoJ, let's assess the situation: the tub was in pretty bad shape, with a lacework of rust holes along both pan edges, and at all the bottom seams. I pulled a sheet of rust off the bottom of the trunk. Plus, the combing was cracked at all four corners.

    It really would have been better off buried halfway in my yard and filled with soil and having rose bushes planted in it, but gotta work with materials at hand, right?

    Obviously, the best way to repair this is to cut out all the rust back to good metal and start welding, right?

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    Nope! After careful thought, I decided it ultimately wouldn't be cost or time effective. And, I can't weld.

    While the frame is in pretty good shape, the tub looks like a terminal case, eventually. Rust is hard to stop once it starts. My thinking was to just get the tub usable until I could afford a better one down the line. I found online a Trunk and Floor Pan Repair Kit from POR-15. While I waited for that, I started with the drill and wire brush attachment....
    #8
  9. MotoJ

    MotoJ Mobtown Hacker

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    ... the bike went on the lift. We're going to address the issue of brakes first. The single disk, even with a stainless line and EBC pads isn't going to cut it. After a lot of searching I saw on a thread BMWEuro (Chris) was parting out an R100, so a few PMs later and I had two sliders, a rotor, and a pair of matching blue ATE calipers. To address the suspension Tom compressed the Progressive springs with 1/2" spacers. The preload should help with dive.
    We're going cheap and dirty here. Someday maybe a LL setup with Brembos.

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    New brakes and sinister looking black sliders and brace! This is more brake than I've ever had on a bike, probably. Still back in the 20th century- sad, huh?
    The fork brace was made by Brad Phillips. I found him on EBay, but he's an inmate too, I think. He's also a Ducati racer. Anyway, nice piece, reasonably priced. I waffled between a top triple clamp or a fork brace to stiffen the front end. I couldn't afford both. By the threads I found here opinions seemed about 50/50, so I went with what I thought I could sell easiest if all this doesn't work out.

    You can see the new /5 fender in the above shot. There's an Enduralast system peeking out back there too. I'll explain later...


    (BTW, sorry again for the crap photos!)
    #9
  10. JimVonBaden

    JimVonBaden "Cool" Aid!

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    This looks like fun! :lurk

    Jim :brow
    #10
  11. Bloodweiser

    Bloodweiser honestly

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    way over yonder in the minor key
    awesome.


    There's definitely a sidecar in the future for me somewhere.
    I'll be taking notes. :deal
    #11
  12. MotoJ

    MotoJ Mobtown Hacker

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    After liberal soakings with PB Blaster and Liquid Wrench over a number of days we were finally able to detach the tub from the frame. I put it in my truck and once home balanced it precariously on a wheelbarrow and got it down the steep sideyard to it's new home behind my house. Up on the sawhorses it went, and out came the drill and cup brush.

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    The tub had been repaired previously and the bottom had some primer and body filler here and there. As I proceeded with the brush, that all started coming off and it became apparent just how bad it really was.

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    From the inside I could see daylight all up and down the bottom of the pan where it made the turn to vertical.
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    It was kind of discouraging, but I had already ordered the POR15 Trunk Repair Kit, so I kept going...
    #12
  13. Ryushin Kan

    Ryushin Kan kancho

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    I'm subscribed!! Great to see a back yard build on a budget - mine's coming I promise! I started with a GRP tub so easier to work with, it's only a fun hack so doesn't need to be strong enough for off-roading.

    :clap:freaky
    #13
  14. MotoJ

    MotoJ Mobtown Hacker

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    I'm not sure what GRP is- fiberglass?
    This project has been a load of fun, although it has taken longer and cost more than I thought, naturally. However, I heartily recommend it to everybody!

    About halfway through messing with the tub I saw on Craigslist a Ural car with a disk brake, lights, new paint for $1500. Way, way more than I paid, but all ready to go.

    When all is said and done though, I'm glad I went the way I did. It's been a bonding experience. I really feel like this is MY rig now. Plus the decisions I made about refurbishing the car and the colors and condition of all the salvage parts I scrounged eventually charted the look of the whole rig. You'll see...
    #14
  15. MotoJ

    MotoJ Mobtown Hacker

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    ...was pretty nebulous from the start. It was definitely made up as we went along. Not having ever driven a rig I wasn't even sure I'd even like it, although I strongly suspected I would. Everyone who has one looks like a grinning fool!

    With that in mind and having little funds as usual, I didn't want to mod the bike too much that it would be really difficult to turn back into a solo. I wanted to make investments that would benefit the bike regardless of having the car slung on it.

    One of my biggest peeves with the Beemer is unless I had a lengthy blast down the highway a few times a week my battery would never stay charged. Most of my commute is through the city, with lots of lights, and the bike never gets revved up. There's a highway loop I can take, but that's only 15 minutes, and not enough time at the higher RPMs. Forget about an electric vest or heated grips.

    So my two biggest expenditures came in the form of the dual disc setup you've already seen and an Enduralast charging system and crank mounted ignition.

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    While the bike was on the lift and we gave it a full service: oil, filter, wheel bearings, steering head bearings, final drive splines and oil. Fresh fluid with the new brakes, and both calipers and the master cylinder were rebuilt. The blue bodywork came off to be saved for something else down the line.

    I couldn't afford a Leading Link front end and it seemed premature to buy one anyway, since this is kind of a toe dip into sidecarring. For the front end suspension we decided on a fork brace and slugs, as I explained. For ease of steering wide bars were in order. I found a pair of (almost) brand new 90s GS bars in Canada on Kiiji for $50, after a Google search.

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    My geniune Dnepr tonneau cover came in same day from "he who must not be named" in Ohio.
    I paid for the bars with a personal check that I mailed the day before I got the bars. The guy had already shipped them! Canadians are so nice! I talked to him on the phone and suggested PayPal and he said, "why not just send a check and save the fees?". It never even occurred to him he might be ripped off. We've become jaded down here in the 48.
    #15
  16. Abenteuerfahrer

    Abenteuerfahrer Deaf on Wheels

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    Great Attack to get it back to it's former glory.

    Why not have it sandblasted at some of the many yards in Baltimore or Boat Yards in Annapolis than this brush grinding?

    POR( Pour on rust) is good. Tough on your hands, beware!

    GRP(glas reinforced plastic)=Fiberglass

    Cannot wait for the finished product....:clap
    #16
  17. MotoJ

    MotoJ Mobtown Hacker

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    Thanks for the support!
    I actually own a hopper and a compressor that would have been sufficient to blast everything, but I couldn't seem to get it together to get the Black Diamond media that I wanted to use. I had tarps I was going to use to catch it all so I could reuse it, different size ceramic nozzles for the gun, yadda yadda. The only place that sold the media remotely close to me was closed on Saturdays and before I got off work, so it never happened. The brush and Dad's zip strip eventually did the trick.

    Eventually I got to here:
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    Notice the potential hack monkey coming out to check on progress (far right). He's all bandaged up from his trip the previous evening to the doggie emergency room after getting his ass kicked by a deer (thinks the vet).



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    And then to here...starting to look like Swiss cheese in places...

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    #17
  18. Ryushin Kan

    Ryushin Kan kancho

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    Thanks for providing the description of GRP Abenteuerfahrer, the time difference doesn't help!

    I'm off to Andy Tiernan's Motorcycle Emporium for a drool :evil later today, will take camera and hope he don't mind me recording some of his treasures - google him if you need to see more! Old school God in these parts.....
    #18
  19. MotoJ

    MotoJ Mobtown Hacker

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    Check this out, guys: http://www.andybuysbikes.com/Bikes.htm

    That leads me to a note about Camp F*ck'n F*ck. My pal Tom, who's been gracious enough to help me with my project, maintains an ubercool little shop here in Baltimore. A great place to spend an afternoon- you never know what will show up. Tom has helped many a rider keep their vintage bike on the road as a daily driver- he's more of a functionality guy than a restorer, although he's done a bit o' that. He specializes in airheads, and he's known as a sidecar guy. He's folk you want around after the Zombie Apocalypse. He could build an escape vehicle out of an old Briggs & Stratton and roller skates...

    Here he is delicately adjusting one of the frame mounts with a BFH...

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    Lock up your wives and daughters! (No, really. Must be the hair...)

    Tom built and raced this /2 based kneeler rig pretty successfully a few years ago...

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    Here it is in action...
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    Some random shots of the Camp...
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    This /5 based rig has been across the country and back numerous times. Need a BIG tank...

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    Here's a daily driver /2 with loads of miles...
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    Here's one of Tom's resurrections. Pieced together from a few bikes and saved from being dismembered on EBay. Now it will accrue many happy miles for it's owner and he'll hardly ever have to stop for gas...

    [​IMG]

    Bikes like this one and all manner of other eclectic rides stop by at random. It's way cooler than any Camp I went to as a kid!
    #19
  20. MotoJ

    MotoJ Mobtown Hacker

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    So now I had to do the interior. More stripper and brushing and then it got the hose again.
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    The POR-15 Trunk Repair Kit came in. Has everything you need. I ended up buying some POR seam-fill extra, too. The trunk repair kit comes with some fiberglass matt. I bought some glass mesh cloth too from Salvo Auto to supplement that. The POR-15 is basically an epoxy paint that hardens just like a glass coat. Paint on the POR, lay down the mesh, paint over with POR. Presto! Floor pan repaired.

    I used the seam fill on all the seams (imagine that) I also used a little bit of Bondo with glass fiber to pack into the major holes. Not pretty, but it should be waterproof and the rust should be arrested. I covered the whole floor nose to trunk with mesh and layed it about 3" up the sides of the tub to cover all the holes.

    The kit comes with an etcher called Metal Ready that arrests the rust and helps form a chemical bond with the POR. That's the cloudy stuff you'll see in the pics. The kit came with black and silver POR. I used it all.

    It's all pretty self-explanatory.....

    I'm going to blast through this process with the pics. This tub stuff is getting boring.

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    #20