Hack Newb Technical Assistance Needed

Discussion in 'Hacks' started by SantaFeTrailer, Mar 7, 2013.

  1. SantaFeTrailer

    SantaFeTrailer Stromtrooper

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    Hi

    I picked up an XT225 that I would like to hack. This is a strictly around the neighborhood and up to school (1.25) mi. rig. The bike is light (267 lb wet) and the sidecar will be too, since with 3 up the little XT might have some trouble making it the hill we live on. I am planning a simple square tube frame with bench seat for 2 monkeys, riding on a torsion axle.

    First a mock up of my car idea. I am thinking I can install three point belts to hold the monkeys in place.

    [​IMG]

    Here are some shots of the bike. It does not have a perimeter frame (the engine is a stressed member to some degree) and there are not many mounting points. This is a small bike.

    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    So, what say your collective wisdom on mounting points/subframe (or the car design)? The footpeg is mounted solidly, so that is one definite point. working something in to the engine mount seems like another good possibility.

    Thanks in advance for the suggestions.
    #1
  2. Qwik

    Qwik Adrenaline Addict

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    Im a newb to this as well but I am seeing multiple mounting points. The Front of the downtube where the motor plate is located is one and the bolt behind the motor (Right by the Yamaha "Y") is another. as well as the Peg mount. Maybe a fourth one clamped the the frame tube?
    #2
  3. Boxer Metal

    Boxer Metal Mad Scientist

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    Some quick thoughts

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #3
  4. SantaFeTrailer

    SantaFeTrailer Stromtrooper

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    Thanks BMWe

    From this pic it seems as if you are thinking 3 point mount? I had it in my head that might be adequate for such a light rig that will probably not see the north side of 25mph.

    [​IMG][/QUOTE]

    When you say "build 2 piece clamp" that is the strap-and-anvil type thing?

    So, basically, just use the points I have, and as many of them as possible?

    Thanks.
    #4
  5. Qwik

    Qwik Adrenaline Addict

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    Fourth point up by the top pillion peg mount
    #5
  6. claude

    claude Sidecar Jockey

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    Great diagrams by Chris!! The front lower can b edon ewith a pllate on each side of th edowntube through bolted ...yes. pic up as many mounting points as possible and connect th edots with tubing. Overkill rules!
    #6
  7. Boxer Metal

    Boxer Metal Mad Scientist

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    When I get over this stupid cold and I'm at the shop I'll take some pictures of a clamp and home made upper struts. You might have to remind me.
    #7
  8. jaydmc

    jaydmc Long timer

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    Make this a one peice sub frame that gives you all 4 mounting points. Start at the front of the frame, the two bolts at the botom of the frame use these and go back on both sides of the bike to the foot peg mounting bolts. Also go up from these two bolts (this part could be bolt on) and as sugested also clamp around the frame. From the rear go up from the sub frame and pick up the mounts for the passenger foot peg.
    Spread the parts as far as part as possible.
    Jay G
    DMC sidecars
    www.dmcsidecars.com
    866-638-1793
    #8
  9. SantaFeTrailer

    SantaFeTrailer Stromtrooper

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    Thanks for the suggestions.

    I played around with some prototyping tonight.


    [​IMG]
    I will double up to the other side as per suggestion.


    A little hard to tell in this pic, but I have a 1x1 upright bolted to both engine mount bolts that I can attach the front upper strut to.

    [​IMG]

    Maybe use this area to mount the upper rear?

    [​IMG]

    and pay no mind to those ugly welds:muutt
    #9
  10. japako

    japako Been here awhile

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    I'm a noob at building a side car also. Have not built one yet..
    But I do a little welding. You should not grind your welds to make them look purty. When doing this you weaken the weld. Use some scrap of the same thickness and practice.
    I like what your doing and plan on doing something similar..
    #10
  11. MILLENNIUM FALCON

    MILLENNIUM FALCON Been here awhile

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    Its great to see some more people putting hacks on small bikes. here is a picture of my xt350 project Ive been working on. My subframe is very similar to yours. I have a few more braces to add but its almost done. [​IMG]
    [​IMG]
    #11
  12. SantaFeTrailer

    SantaFeTrailer Stromtrooper

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    #12
  13. SantaFeTrailer

    SantaFeTrailer Stromtrooper

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    Well, its alive. I rode around the block and it didn't handle miserably at least. That's a whole different beast to ride, huh?

    Lots of work to go on unit, subframe, etc. but hopefully I'm on track to have something to ride around Overland Expo.

    [​IMG][/IMG]

    I switched to the stick welder and I am getting better results with that. Some welds aren't even embarrassing!

    [​IMG]

    This is more representative: decent penetration but ugly:

    [​IMG]

    I am having a problem on the superstructure which is thinner metal. I have the heat turned down as far as I can and still strike an arc but it is burning through. Japako, what do you think? Maybe need smaller rods?

    [​IMG]
    #13
  14. cleatusj

    cleatusj Dirt floor engineer

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    3/32 or 1/16 rods and move faster. Just my .02.
    #14
  15. SantaFeTrailer

    SantaFeTrailer Stromtrooper

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    Thank you.
    #15
  16. boxertwin

    boxertwin Long timer

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    Below is a link to my DRZ build. There's lots of ways to make this work. This was my first project, it ain't pretty, but it did work well. The parts that I want to point out are; I was able to have a narrower rig by seating the passengers one in front of the other, with roll cage protection, and five point harnesses by using car seats.
    The attachment points to the bike worked well.
    I would not use a dirt bike swing arm with linkage to the shock as I did. It makes for an easier project but adds in several problems...in my humble opinion.

    http://boxertwin.smugmug.com/Other/Hack/9828482_dMbJDQ
    #16
  17. Old Mule

    Old Mule Been here awhile

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    Very nice job on that tandem seater.
    #17
  18. bmwhacker

    bmwhacker Still on 3 wheels

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    :clapThis oughta be a perfect "Munchkin Mobile" for the young'uns!

    I also have a feeling you'll be called upon to make an occasional "beer run" too.:freaky

    [​IMG]
    #18
  19. JPierce

    JPierce n00b

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    I've been thinking about a small cc hack, but I haven't settled on which tug to use yet. Leaning toward my old Honda SL350

    For stick welding, smaller diameter rods, keep your arc short by holding the rod closer to your metal, angle it to distribute more heat the thicker piece if the two pieces are different thickness.
    Easier to do than to explain
    #19