Ultimate ourback sidecar (I hope) build.

Discussion in 'Some Assembly Required' started by 3legs, Jan 8, 2010.

  1. 3legs

    3legs Real men ride sidecars

    Joined:
    Oct 3, 2007
    Oddometer:
    1,176
    Location:
    Adelaide,South Oz
    G'day

    I've always had an idea in my head for what I would want in a sidecar built for the harsh Australian outback. In Australia it's bloody easy to get lost or break down 100's km's from the nearest town and even in this day and age people still die in the remote areas from thirst or heat or both after they have broken down. In a lot of cases needlessly because they usually break the golden rule of leaving their vehicle.

    I was going to build it after 2010 OCR but Gad sort of challenged me to do it (he didn't really but he did describe it as a wet dream so bugga it I took it as a challenge). So I'm going to try and get it finished before the 2010 OCR.

    It's only the body and chassis I will be building and I will attach it to my K1100 (swap it for my camper outfit). I will probably turn a BMW R100 into a chookchaser and attach it to that at a later date.

    The design brief was simple. It must be as light as possible but strong. It must carry the normal stuff as well as emergency equipment, recovery gear and enough fuel to cover at least 600 kms and water for at least a week.

    It will have back systems eg: It will carry a PLB (epirb) as well as a SAT phone. It will have 2 suspension systems in case one fails. It will have swingarm/shock suspension as well a 300kg flexitor (torsion bar) suspension system which will be the back up. It will also have an air compressor as well as a hand pump for punctures.

    It will have a dual battery setup so I can run my fridge (got to have a cold beer at the end of the day) and be able to use my welding setup. Will also have an invertor/ power convertor or what ever they are called so I can run a drill or angle grinder.

    The fuel will be carried in 10L jerry cans rather than 1 fuel tank mainly because I've holed a 10L jerry can on the Birdsville track and had it been a 20L can I might have been in trouble. If one is holed at least I will have others with fuel in it.

    It won't be pretty (just like most of the inmates here, except me of course:D :D ) but it will be functional. Every inch of space will be utilised.

    It will have a twin jet gas stove (as well as my barby plate,cant go anywhere without that). Also enough tools to tear the motor down and rebuild it if I wanted too.

    Here's a some photo's......

    [​IMG]

    The metal for the chassis and frame. It will be covered in Ali sheet.

    [​IMG]

    Believe it or not this lot will fit inside or outside the chair. It looks a lot and it is but most of the stuff is faily compact when packed properly.

    [​IMG]

    This is the welding setup that I can run off a dual battery.

    [​IMG]

    This is the PLB (epirb)

    [​IMG]

    A pair of traction mats.

    [​IMG]

    A winch which will be mounted up front on the main chassis rail.

    [​IMG]

    The 20L water can. It has a 12v pump inside and a tap will be at the back. Im a lazy bastard and at a push of a button I will get water rather than lifting the bloody thing out for a cuppa.

    So there you have it. I was going to start on the chassis today but it's 41 degrees and 43 degrees the next 2 days. Too bloody hot to be in a shed. So I probably wont start until next weekend. At each stage I will take photo's.

    Im open to any suggestions of what you would like to see incorporated in a sidecar. I'm not a professional builder so don't expect perfection. It will be rough but it will work and it will be strong (i've made others in the past and they have never broken on me) so if a weld looks like crap please dont give me a hard time otherwise I will have to take it out on my body and consume copius amounts of alcohol to relieve my stress.

    3legs

    Ps. TD and Clancy....the race begins:D :D :D
    #1
  2. brianrees

    brianrees n00b

    Joined:
    Jan 8, 2010
    Oddometer:
    3
    Location:
    perth australia
    mate love what you are envisaging to do and carry , first thought , throw away that pile of tube you intend to make it out of, go buy some round chrome moly tubing , strong,light and round, round tube equals strength square tube isn't for things that flex ,actually it looks like a pile of racking steel to me ?, i appreciate you say your welds have never broken ,it isn't the welds breaking that are a problem (welds can be re welded) its the tubing's integrity , PS the weight of the square tube to chrome moly x strength would be a fair difference, and i have got a slime unit have a look at their website ,there is an Australian agent in each state or repco i think it is , their bike unit is great small very good compressor with slime and all the stuff needed to fix a puncture on the outback roads and i fit the lot into the tool box on my Suzuki vl 1500 well worth for space and weight .:1drink
    #2
  3. 3legs

    3legs Real men ride sidecars

    Joined:
    Oct 3, 2007
    Oddometer:
    1,176
    Location:
    Adelaide,South Oz
    Hi Brian

    Your'e right about the round moly and I did think about using it but I deliberately wanted to use square because it's easier to mount things to and weld (and I've only got an arc welder, no mig or tig and it keeps the costs down) and I dont want to have to have round shapes to form sheet metal/ali around. I'm a huge believer in this K.I.S.S principle.

    I hadn't thought about the slime. Must check that out.

    Thanks for the input. Keep it coming.

    Cheers

    3legs
    #3
  4. Medic

    Medic Window licker

    Joined:
    Jun 18, 2009
    Oddometer:
    598
    Location:
    Tanah Merah, Queensland AUSTRALIA
    This all seems worth a look, keep it coming.
    #4
  5. Threewheelbonnie

    Threewheelbonnie Long timer

    Joined:
    Oct 20, 2008
    Oddometer:
    1,019
    Location:
    Yorkshire UK
    Sounds exactly like the outfit I'll built when I have the time, the money and the skill :D

    I'm totally with you on the steel box section. Every mine workshop, truck stop and general fabrication place in most of the world has a couple of lengths they might part with to help a traveller out and the means to weld it. Show them moly coated tube and you get offered scaffolding pole!

    I'd want to make as much as I could interchangeable. Use three shocks all the same, use the same electrical connectors as on the bike and so on so if something falls off you can bodge together a repair doing as little damage as possible even if you've already raided the parts strore. Nuts and bolts wise I'd even go so far as to buy a bucket of two sizes and not use anything else.

    Can't wait to see the result.

    Andy
    #5
  6. snayle

    snayle Adventurer

    Joined:
    Oct 8, 2007
    Oddometer:
    217
    Location:
    yorke peninsula south australia
    And where does the food (prawns) go

    snayle:lol3
    #6
  7. 3legs

    3legs Real men ride sidecars

    Joined:
    Oct 3, 2007
    Oddometer:
    1,176
    Location:
    Adelaide,South Oz
    In your fridge. Not going to put smelly prawns in my fridge mate.

    3legs
    #7
  8. snayle

    snayle Adventurer

    Joined:
    Oct 8, 2007
    Oddometer:
    217
    Location:
    yorke peninsula south australia
    ah but I am selling my out fit so you will have to carry it all yourself,
    and learn to cook!:lol3
    #8
  9. 3legs

    3legs Real men ride sidecars

    Joined:
    Oct 3, 2007
    Oddometer:
    1,176
    Location:
    Adelaide,South Oz
    Bastard
    #9
  10. brianrees

    brianrees n00b

    Joined:
    Jan 8, 2010
    Oddometer:
    3
    Location:
    perth australia
    reminds me of the quote , (slightly altered)

    Give a man a prawn and he'll eat for a day. Teach a man to catch prawns, and he will sit in the boat and drink beer all day
    #10
  11. snayle

    snayle Adventurer

    Joined:
    Oct 8, 2007
    Oddometer:
    217
    Location:
    yorke peninsula south australia
    Oh to true brian but in the 25 years I have known Alex,
    I have allways cooked extra food for him! He did try and cook
    for us once but boiled the pot (camp oven) dry !

    The only thing you can teach a 9 mile sniper is to shoot things
    and give the carcus to us tucker fu##ers

    snayle
    #11
  12. Andrew2

    Andrew2 Team 250

    Joined:
    Aug 3, 2005
    Oddometer:
    5,308
    Location:
    Wollongong,N.S.W.
    Hey fella,
    if I were to put a winch on my sidecar I might make it so I could take it off the front and mount it on the back as well if needed.

    Cheers
    A2
    #12
  13. 3legs

    3legs Real men ride sidecars

    Joined:
    Oct 3, 2007
    Oddometer:
    1,176
    Location:
    Adelaide,South Oz
    G'day Andrew

    Good idea Andrew. Hadn't thought of that one. Might have to do some drawings to figure out a quick release mechanism to do that very job.

    Snayle the only reason why I cooked the camp oven dry was you lead me astray and got me horribly pissed and we BOTH forgot about it, mind you that seems to happen a lot when we get together. :D

    3legs
    #13
  14. brianrees

    brianrees n00b

    Joined:
    Jan 8, 2010
    Oddometer:
    3
    Location:
    perth australia
    good god im not conversing with a drop short:dj and a bait layer:puke1 am i ?
    #14
  15. 3legs

    3legs Real men ride sidecars

    Joined:
    Oct 3, 2007
    Oddometer:
    1,176
    Location:
    Adelaide,South Oz
    Yep
    #15
  16. snayle

    snayle Adventurer

    Joined:
    Oct 8, 2007
    Oddometer:
    217
    Location:
    yorke peninsula south australia
    maybe
    #16
  17. Clancy

    Clancy Long timer

    Joined:
    Jun 11, 2006
    Oddometer:
    6,020
    Location:
    Land of droughts, and flooding rains
    Watching with interest Alex:evil

    So far, you got all my ideas covered:lol3 That's a good idea of Andrew's too. I was going to suggest it but he beat me to it:clap

    What wheels? I'm going to have the rear bike wheel and the sidecar wheel the same.

    And you'll probably still finish before me:lol3
    #17
  18. choccoloco

    choccoloco Cabin Fever....

    Joined:
    Mar 4, 2008
    Oddometer:
    798
    Location:
    CBR, AUS
    :lurk

    The only time I've ridden with scray, was when I saw the need for the ability to mount the winch to the rear too. :amazon

    This looks like an interesting project.
    #18
  19. miggins11

    miggins11 Been here awhile

    Joined:
    Nov 18, 2009
    Oddometer:
    213
    Location:
    Cheshire, England
    I'll be watching from the other side of the world!
    #19
  20. johno

    johno Long timer

    Joined:
    Dec 31, 2007
    Oddometer:
    2,912
    Location:
    Mount Gambier, South Australia, Australia.
    :lurk This will be interesting 3legs:D I love these Aussie buildups.
    #20