Dual Sport Trailer assembly thread

Discussion in 'Some Assembly Required' started by The Cheat, Jan 13, 2006.

  1. rw4x4van

    rw4x4van East Coast Rider

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    Mr Bracket.....where are you located
  2. MrBracket

    MrBracket Been here awhile

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    Hey guys,

    I live in Springfield Oregon, only a couple miles from ProCycle. I know the guys over there, when I mentioned the trailer to them they were excited about it. They have seen it evolve over the past few months and were more than willing to test it out for me.

    I'll get a few pics posted of the lights ProCycle mounted on it. You can see in the road video I posted that they had a brake/tail light mounted on it. I've been told they added turn signals now too. I believe they are interested in selling a lighting kit for the trailer.

    I already ordered the wheels and shocks, so the first five trailers will have the same color scheme as the prototype. They will have black frames with the red rims and red shocks. After this initial produciton run I hope to have a better idea what they cost to produce and would be able to have an idea what other options like colors and such might cost.

    I've already had a couple serious emails from people that want one of the first five. I should be clear also, there will be five availiable, I already had another wheel and shock to build the one for the guy over at ProCycle, his will be frame number 0001. The five availiable will be frames #0002 through #0006. I have mentioned to the people that emailed me that I will also throw in a few extras with the first five trailers. I am ironing out the details on a fender for the trailer, the first five will get one at no extra cost. Also, I will put together a fastener kit if you plan to use a Rubbermaid Action Packer tub, not a big deal, but it will keep you from having to run to the hardware store.

    I am taking measurements today of a couple KLR's so I can make a hitch to fit those bikes. The KLR does not have a large enough hole through the axle to work with the trailer. I will make a couple adapters that will fasten to the swingarm of the KLR allowing the trailer to mount to them. I hope to have that figured out here soon so KLR owners could take advantage of one of the first five trailers as well. The KLR hitch will cost extra, I don't know how much yet.

    Thanks again!
    Mike
  3. Wlfman

    Wlfman Long timer

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    Put me on the list for a KLR setup when you get them figured out. Email sent
  4. MrBracket

    MrBracket Been here awhile

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    Alright KLR650 guys... Does this look like your swingarm/rear axle arrangement?

    [​IMG]
    [​IMG]

    I was told that this is a 2006 KLR650 and that the swingarm/rear axle assembly was the same from 1987-2007. KLR guys, is this true? If you have a KLR and are interested in a trailer, is this what yours looks like?

    If so, I'm working on a hitch solution for the bike in this picture. I'll keep you posted as to what I come up with.
  5. Wlfman

    Wlfman Long timer

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    Yes, that's it. 87-07 all the same.
  6. TWT Rider

    TWT Rider Riiiiiiide

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    I can put my Trailer on it with a minor Axle mod, and it works awesome
  7. ben2go

    ben2go Moto Flunky

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    Can we see that please?
  8. walkergreenlabel

    walkergreenlabel Been here awhile

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    I was laughing when I watched the video when you hit the trails pretty hard! how much weight was in the trailer for that video?

    Is the bracket to the bike axle fixed or does it rotate around the axle? Do you have any mounting ideas for an XR650R?

    how many of the first run are left?
  9. TWT Rider

    TWT Rider Riiiiiiide

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    I shouldn't say easy mod, as it is a bit costly. What I've done a few times if make a custom axle where my Trailer attaches to. But it does work very well
  10. wdeTA

    wdeTA TransAlp Adv

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    I don't know about the KLR, but it's very similar to my Transalp. If you can make it work for that as well I would be very interested.
  11. MrBracket

    MrBracket Been here awhile

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    In the Trailer Cam video I had about 25 pounds in the trailer. Just a tool bag, rain gear, and two sleeping bags. I stuffed the sleeping bags in there to keep the tool bag from flying around inside the tub.

    The hitch setup allows the trailer to rotate "up and down" by rotating inside the axle of the motorcycle. It "turns" left and right in the upright tube behind the rear wheel of the motorcycle.

    I'd need to know the overall length of the rear axle on the XR650R as well as the inside diameter of the axle. I do know that the XR650L has too small of a hole through the axle to work with this trailer. You need to be able to stick something 3/8" in diameter clear through the axle.
  12. MrBracket

    MrBracket Been here awhile

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    Here is what I have come up with for the KLR....

    Start with this:
    [​IMG]

    Remove this:
    [​IMG]

    Now looks like this:
    [​IMG]

    Trade old for new:
    [​IMG]

    Install New: Mirror image on other side, two brackets total.
    [​IMG]

    Leave this on at all times if you like, should stay out of the way:
    [​IMG]

    Now you can pull a Moto-Mule Trailer:
    [​IMG]

    Closeup:
    [​IMG]
  13. ben2go

    ben2go Moto Flunky

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    That's a nice set up.How much would just the adjuster plates cost?I think they may fit my GS500.
  14. MrBracket

    MrBracket Been here awhile

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    A lot of people have expressed interest in the first five production trailers. I don't want to take anybody's money yet, not until the trailers are actually done and ready to ship. What I've decided to do is start a list of people who have emailed me about wanting one of the first five. I'll keep track of who was first to contact me and they will be at the top of the list. I'll start at the top of the list and contact people when the trailers are done and collect money then if they still want a trailer. If not, I'll work my way down the list.

    To get on the list, I need you to email me your name, screen name too, your bike info, and the best way to contact you. My email address is mtsfabman@yahoo.com you can also just PM me here on the board as well if that works better for you.

    This seems to be the most fair way to handle this promo deal as I don't want to take anyones money yet.

    So far the list is as follows:

    1) c2c4c, 2002 DR650
    2) Wlfman, 2006 KLR650
    3) Screen Name, ???? XR650R (will need data on axle to make sure it will fit)
    4) Cromoth, 2008 WR250R
    5) WalkerGreenLabel, XR650R (will need data on axle to make sure it will fit)
    6)
    7)

    Is it ok to post screen names on this list so you know you are?? I don't want to offend anyone or break any rules.. If you think you are on this list and don't mind me posting your screen name, pm or email me and I'll put your screen name up here.

    Thanks,
    Mike
  15. MrBracket

    MrBracket Been here awhile

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    I'm going to start out with offering them for $50 a set for this first production run. The trail tail KLR setup sells for $250 and appears to be quite bulky??? Not bashing, just pointing out some differences.

    I'd need dimensions of your GS500 adjuster plates to see if they would fit.
  16. Dblarrow

    Dblarrow Been here awhile

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    As a KLR driver I have been wanting a trailer like this myself. Looking at this my concern is the strength of the bolt and the threads of the bolt and the total weight of the trailer. Do you have an empty trailer weight yet?

    Nice job so far.
  17. MrBracket

    MrBracket Been here awhile

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    The only load on the bolt will be tension as there is a shoulder on the back edge of the plate that slides inside the swingarm. I do not have a total weight of the trailer yet, I took it all apart to build welding fixtures. I'll weigh it when I get the first one done.

    I did get the shocks in today! :clap

    [​IMG]
  18. MotoBoss

    MotoBoss Bad Influence

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    Great job on the KLR plate fab! On the list. eMail sent
  19. ag_streak

    ag_streak Tiene Ruta Cuarenta?

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    That's a very elegant solution and I appluad your skills, but I'd be concerned about the stresses on that stock axle puller.

    As designed by the factory, that pin holds the axle back away from the pull of the chain. With that plate you designed pulling the trailer, all the tension would tend to pull the axle back in the swingarm. The only thing keeping the axle from moving would be the friction of the axle bolt.

    In other words, if the friction on the axle nuts holding the axle in place against the swingarm was overcome, the axle would move backwards, tightening the chain. It could move back suddenly or slowly, and evenly or only on one side, cocking the axle out of alignment

    I'm not criticizing in any way! I think your design is very cool, and I only point this out in the interest of engineering and safety! :freaky Just something to think about?
  20. Dblarrow

    Dblarrow Been here awhile

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    Thanks, since you don't know your trailer weight - what are your spring weights on your shocks here? and how do you know how to size them? As light as this trailer is, is the shock going to absorb the bounce? I pulled a trailer behind a CB 750 and the shocks were to stiff and the thing just bounced around and stuff inside the box just took a beating....

    Understand the shoulder on the plate, I was referring to the possibility of stripping the threads off the bolt? If that is a dumb question bummer, I am a wood guy and wood trailers don't hold up as well!!