Martin's VTR 1000 Adventure Sidecar Build

Discussion in 'Hacks' started by m_cliffhanger, Nov 4, 2016.

  1. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    As the frame is coming off the build table, it was a good time to install the tapered roller bearings in the steering head. The beefiness compared to the stock bearings and races, is quite amazing. I also appreciate Honda's foresight; there are two small recesses machined into the bearing seat, so the bearing race can be tapped out with a long punch. Nice.
    IMG_8404.jpg IMG_8403.jpg
    #61
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  2. cog8603

    cog8603 Been here awhile

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    Looking good. when do you expect to have this baby back together? I'm looking forward to seeing the final result!
    #62
  3. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    Thanks, Dave. If I can get a couple of test rides in the fall, I'll be happy. Then I have all next winter to fix what I don't like or doesn't work. :baldy
    #63
  4. cog8603

    cog8603 Been here awhile

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    you have FAR more patience than me. I'd be spending way too much time on it until it was done. :D
    #64
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  5. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    Welded in the brace for the leading link. Staid straight, so all is good.
    The base frame is coming together. I've welded in three 1/2 inch bosses, which will be for the vertical mounts. The swingarm is attached to, what I call the spar, since most of the loads will be fed into it. The base is 63 in x 31 in, however, the body will be narrower and longer. There will be a rear roll bar, or hoop, and possibly a smaller front hoop, which is part roll bar and hand hold. But I still have to configure that. IMG_8407.jpg IMG_8406.jpg IMG_8410.jpg
    #65
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  6. cog8603

    cog8603 Been here awhile

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    did you run the bolt on the inside of the swingarm through the tube frame too?
    #66
  7. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    No. The picture is a bit deceiving. There is about a 3/4 in gap between the bracket and the frame rail. Enough to get a nyloc nut in there. Once torqued up, the brackets will pinch the inner bushing sleeve, so that the urethane will rotate on it.
    #67
  8. Old Mule

    Old Mule Long timer

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    Look at all those files. You must be old.
    #68
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  9. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    Points were something I set between heats; they weren't much good as payment for airline tickets. :baldy
    #69
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  10. bk brkr baker

    bk brkr baker Long timer

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    A large platform. Are you planning for group rides ?

    [​IMG]
    #70
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  11. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    With two young daughters, shuttling them and their friends fourteen times a day, maybe not a bad thought. And with the new driver/learner rules, this might be an interesting future option; get my daughter to do her M/C learners first . When I got my learners, it was automatically my job to chauffeur my siblings. Not so today. :baldy
    But I digress. I'm planning to make the body/tub narrower and to mount it inside of the rails. The roll bar will actually be outside of the body. I think that it will make fabricating it easier. I'm still at 50" to 51" track.
    The styling department may need a few more beverages before their visualizations can be turned over to fabrication. Damn hierarchy.
    #71
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  12. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    The sidecar suspension is nearly done. Just need to finish weld the braces, but for that I'll need to flip the frame. I found the shocks on Ebay a while back, and thought they would be worth a try. They are NOS, and came in the original box, with a T-shirt offer from 1975. :imaposerI've read about the drawbacks of air shocks, but I like the idea of infinite spring settings, since at this point, I don't have a clue what a good starting point would be. I also like that little fingers can't be pinched, as the shocks will be exposed. In the forward setting I have 6" of travel, and 4.5" in the rearward. I will probably set it up with about 2 1/2" droop and 3 1/2" bounce. IMG_8414.jpg IMG_8416.jpg IMG_8415.jpg
    #72
  13. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    Changed my mind on the size of the base frame. After mocking everything up, I decided that I'd like more width between the bike and the frame. So the frame was cut, inserts made and re-welded. The rear roll bar is made, but the final position will be determined by the seat, which should be here next week. I'm still planning on a separate body that will fit inside of the frame structure; I was thinking of a fibreglass tub, but now I'm leaning back to aluminum or steel. I've always wanted to add metal shaping to my jack-of-all-trades-master-of-none list; been looking for an English wheel for some time.
    In the meantime, I've started on the bottom attachment clamps. They are possibly the most critical welds of the project, and a bit fiddly. To get a long and strong bead, the bolt sleeve has to be long, but that means a deep root for welding all around. I need about 1/2 inch of stick out to get down there. Luckily, it is a weld that needs to be cut on purpose, so inspection is a cinch. IMG_8423.jpg IMG_8427.jpg IMG_8426.jpg
    #73
  14. cog8603

    cog8603 Been here awhile

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    so, you're planning to mount the v-twin on the back end of the sidecar? :rofl

    for a jack of all trades, you do exceptional work!!!
    #74
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  15. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    Thanks, Dave.
    So you figured out my secret plan. That's just the engine for the sidecar; you should see the one for the bike. :lol2
    #75
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  16. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    No comment. :imaposer
    IMG_8428.jpg
    #76
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  17. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    What else would they be? :D
    IMG_8437.jpg IMG_8435.jpg
    #77
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  18. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    The rear roll bar is completed, but still needs some finish welding. The seat looks like it will work, and I positioned the roll bar cross brace for attaching the shoulder belts. There will be another roll bar/hand hold to match the rear, but probably a bit smaller diameter. However, the main reason for going that way, is to provide another, strong attachment point. There is a beefy boss about half way up on the rear cylinder, where the frame and slider attach to. It should provide a lot of lateral support, and with a horizontal link, tie into the vertical part of this roll bar. IMG_8447.jpg IMG_8448.jpg
    #78
  19. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    Did a mock-up today, as it is sometimes hard to maintain perspective, when you are always working up on the build table. The bike sits on a 10 inch dolly, so that would be full droop. I need to lengthen the rear shock mount, and lower the front by about an inch, and then it will be level. That should give me a ride height of about 7 in. Wheel lead is 9", which is just under 15% of the 61" wheel base; I can adjust the lead by about 1" either way. IMG_8472.jpg IMG_8471.jpg
    #79
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  20. m_cliffhanger

    m_cliffhanger Momentary Lapses of Reason

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    Built a rad support frame. Had been scratching my head for a long time over this, because the original location requires the full fairing and ducting, and with lower speeds and higher loads, I don't think that there would be enough airflow. I had planned a radiator in the sidecar nose, but couldn't find one low enough to fit. So I came up with this; not very elegant, but should get good airflow. The cardboard is the beginning of a shroud, that will help keep the air from spilling around the rads.
    Also bent the forward roll hoop. It took my little bender to its max, as it got stuck on the final bend, and I had to disassemble the whole thing, to get the hoop out. It will also support and shape the front body panels. As mentioned before, there will be a horizontal link from this hoop to a very solid engine boss, adding a good amount of rigidity. IMG_8482.jpg IMG_8483.jpg
    #80