Nevgriff64 new toy, an Aussie built Ural+BMW 1150GS

Discussion in 'Some Assembly Required' started by McCardigan, Jul 2, 2009.

  1. Shmerel

    Shmerel

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    i suggest you look closely at clancy's project. interesting.
    a few of us are watching, and might follow as 2nd generation prototypes. :deal
    #81
  2. Sylvia

    Sylvia vir sapit qui pauca loqui

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    taking pics
    Been watching Gad,
    I have been for a few years but, must resist, the bastards keep calling.

    All we need now is for Nev to roll along and bust me peeking
    #82
  3. Shmerel

    Shmerel

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    mungo. what happens there stays there. see you then.:deal
    #83
  4. WhatMeWorry?

    WhatMeWorry? Unspoilt and Unspoken

    Joined:
    Jul 7, 2009
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    Gippsland
    Is this tongue in cheek ?? If so, meh...

    Phyllis is the guru. Yiz are all f**** lucky he loves HIS work and not the $$$$$ - otherwise he'd be a gazillionaire by now.

    For a long time now I have wondered why he hasn't got a shop somewhere and making some real pineapples and gorillas ($$$). I think he just couldn't handle Mr. Joe Nobody (customers).

    Why dont you old farts (in Melbourne) band together and get a shop up and running ??

    Me and him don't always see eye to eye..
    But the RESPECT and ADMIRATION is unfathomable..

    She sells sea shells by the seashore ?
    #84
  5. Clancy

    Clancy Long timer

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    :wink: :lol3 Is that you Geoff?
    #85
  6. WhatMeWorry?

    WhatMeWorry? Unspoilt and Unspoken

    Joined:
    Jul 7, 2009
    Oddometer:
    5
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    Gippsland
    No...

    Could call me a junior "Ballast".
    Getting right out the box over the 3rd wheel on tight lefthanders, head narrowly missing signposts..

    Done a lot of "Ballast" work with Phyllis over the years....
    :rofl
    #86
  7. Clancy

    Clancy Long timer

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    Good to see you in here "Junior":thumb
    #87
  8. TouringDave

    TouringDave Tri Moto Veritas

    Joined:
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    Frankston, Vic, Aust.
    So, who is it?
    #88
  9. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

    Joined:
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    Well guys and girls, the build is almost complete.. :wings

    Phyllis ( :bow ) has been kind enough to photo/document the build as he has gone along and i`m happy to share for all that is interested but first a bit of a run down on the why`s and what for`s.. :wink:

    I guess it started with a trip up to the Mungo Nation Park for an ADVRiders gathering late last year.. A trip that had me riding in soft sand for the very first time on a KTM 950 Adventure.. The bike did it easily enough but I certainly had way too many anxious moments to say that I enjoyed myself.. Managed to make the journey without dropping the bike but I think it was more good bike/luck rather than good rider skills.. Two or three didn`t make the gathering with spills that saw both man and machine in pretty bad ways.. ( Hi Sylvia, 1WD, S2W.. :wave ) It wasn`t long after that trip that I decided to have a sidecar built thinking that 3 wheels had to be safer than 2, afterall, I`d seen a few guys riding them and didn`t look that hard to ride.. :huh

    I liked the concept of offroad ability with seating for my children and to carry camping equipment when needed.. Had seen a few pictures of Mickpa`s outfit and thought that that was what I wanted.. Found a Ural sidecar on the internet that had come from an outfit that had an excursion into an embankment, bike had been written off with only minimum damage to the chair.. Perfect for what I wanted.. A 2002 BMW 1150 gsa came up not long after in very good condition with only 17 500 odd kilometers on the clock and was lucky enough to catch the wife in a good enough mood to allow the purchase.. :clap

    Chris McArdle gave me a few builder contacts more than capable of the completing the task but one stuck out more than the others.. With a quick chat to Phyllis ( :bow ), his passion for sidecars for both building and riding was second to none and with an Aircraft mechanical background, I knew he was the one if he`d agree to taking it on...........
    #89
  10. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    Once Phyllis ( :bow ) had cleared his work load, it was now time to start on my project.. WOO HOO.. :clap



    Here`s the BM at the ready to be transformed into what many say is the most fun you can have with your clothes on.. :wink:

    [​IMG]

    Didn`t take him long to remove all the unnecessary items such as crash bars, sidestand, centre stand etc..

    [​IMG]

    Here in Australia, we need to mount the sidecar on the left side of the tow vehicle so alot of thought went into the best way to make the mounts..

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    Here`s a close up of where the centre stand attach point is..

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    25 mm thick Aluminium block was made..

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    #90
  11. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    The rear upper mount plate made and mounted..

    [​IMG]

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    The BMW needs a subframe and here`s a view of the right hand side..

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    A close up of one of the mounting lugs of the subframe..

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    A bit of work is needed to "true" up the case lug..

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    7/16" bolt works well here..

    [​IMG]

    Having spoken to me a few times now, Phyllis ( :bow ) decided his normal crash test dummy wasn`t needed as a worthy replacement had been found.. :huh

    [​IMG]
    #91
  12. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    The subframe in progress.. Note the two extra holes in the mounting block..

    [​IMG]

    On one of my visits, I was asked to sit on the bike so Phyllis ( :bow ) could see where my legs sat comfortably.. The green tape was used to trace the outline of my legs so nothing was mounted in those spaces..

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    A view of the oil filter and crankcase lug..

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    With the subframe nearing completion, it was now time to turn the attention to the upper mounts..

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    The two fasteners that will be used to anchor the forward upper mount..

    [​IMG]
    #92
  13. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    Another angle of the 25 mm Aluminium block..

    [​IMG]

    and again from below..

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    The lower attach arms begin to form..

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    Inside and outside diameters machined.. Bolt support tubes formed ( drilled )..

    [​IMG]

    Needing a bit more room.. :lol3

    ( Note straight edge )

    [​IMG]
    #93
  14. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    Clamps now in place on sidecar frame..

    [​IMG]

    Setting toe in, lead and track..

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    note tape on muffler..

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    still measuring..

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    AND AGAIN!!

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    Sidecar arms in progress and coming along nicely..

    [​IMG]

    As reported earlier, the sidecar was purchased from a vehicle involved in an accident so anything that didn`t quite look right needed close up inspections..

    Forward inboard corner of sidecar frame..

    [​IMG]

    A little rusty, is that a crack??

    [​IMG]

    Close up of suspect area..

    [​IMG]

    Arms and clamps now well under way..

    [​IMG]
    #94
  15. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    Lug almost off..

    [​IMG]

    Corner brace removed.. ( lower arms in background )

    [​IMG]

    Both bracket and lug now removed..

    [​IMG]

    How much of the overhang should be cut off?? :dunno

    [​IMG]

    Should be safe to cut almost all of it.. :wink:

    [​IMG]

    Now, how to plug the end?? :huh

    [​IMG]

    Dog giving second opinion.. :lol3

    [​IMG]

    and coming up with the better idea.. :shog

    [​IMG]
    #95
  16. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    Setting up again.. ( note dead computer )

    [​IMG]

    Phyllis ( :bow ) just loves computers and more than happy to use it the way it was designed.. :lol3

    [​IMG]

    Forward upper mount block and rod end..

    [​IMG]

    [​IMG]

    [​IMG]

    Rolling on 3 wheels for the very fist time.. :rayof

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    View over sidecar wheel..

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    View from behind..

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    General view of mounts..

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    [​IMG]

    [​IMG]
    #96
  17. nevgriff64

    nevgriff64 Spelt with 2 ffs Super Moderator

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    More to come tomorrow.. :thumb
    #97
  18. koifarm

    koifarm Twas ever thus!

    Joined:
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    1,800
    Location:
    Saint Augustine, Florida
    I am totally impressed by the work you gents are doing. And for posting the process, I thank you!
    It follows the entire sequence of designing and mounting a custom sub-frame, to modifying the frame and creating new mounts for that. Not only that but following the set-up process to the recommended specifications for sidecar mounting. The work is first rate from what I can see and is well thought out, even the dog had good input, and looks structurally sound plus 10.
    As a relative newbie, it is a tremendous lesson in how to set up a car frame properly and in a workmanship like manner with lots of creativity thrown in for good measure.
    I'm looking forward to seeing the rig when it's finished.
    Again, many thanks for allowing us to see the process on the forum here, I know it takes much time to snap pictures which suspends work for a bit each time, but it's invaluable for others to be able to see exactly how a superb rig is put together from all the bits.
    :bow:thumbup
    koifarm
    #98
  19. farawayman

    farawayman Been here awhile

    Joined:
    Feb 23, 2005
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    549
    Looking good Nev and Phil, cant wait to see it on the road. Will it be ready monday? I'm happy to give it a test run. :lol3
    #99
  20. johno

    johno Long timer

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    Mount Gambier, South Australia, Australia.
    Come on Nev, its 10am, and no pics:ddog Lift your game mate:lol3

    Looking good, soon out there wobbling all over the road:lol3