WUMPA - my DMC Dauntless 1150GS Adventure rig

Discussion in 'Hacks' started by DRONE, Apr 26, 2011.

  1. davebig

    davebig Another Angry Hun !

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    Drone likes lots of spring so does Stroker and Mikepa destroys expensive shocks, you guys all have big heavy rigs and load them up to go wandering.It all seems too stiff to me but I haven't enough experience yet.I have 2 numbers higher at both ends than Ohlins recommends for a GS on PPS's recommendation. So I'd better wait and see.I'm pretty sure Drones not guilty of any craziness like getting the rig airborne but Strokers definitely a loose cannon.
    I'd want more sag than 5/8" but who knows on a hack, the problem being I don't think one wants the shock to top out going over small rises fast.Onward and forward.
    I think I hate my 2 battery setup but am still waiting for stuff from E Beaver, before I make up my mind.Don't ask the Queen Bee crawl around the garage measuring your rig,but again I lack experience I'm older than you and a bachelor ! DB
  2. DRONE

    DRONE Dog Chauffeur

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    Man, some of the cool stuff guys are doing this winter, like Zipper's build, and BMWEuro's 1150GS! I'm a little embarrassed to post up my next mod. All I did was add 2-1/2 gallons of extra gas in a CARB-compliant plastic bottle.

    <iframe src="http://www.youtube.com/embed/6UHHuVGtFGI" allowfullscreen="" frameborder="0" height="315" width="560"></iframe>


    I picked this particular bottle because the spout system actually works! It doesn't drip or leak, and dispenses fuel accurately into the tank (and not onto the tank) when needed. Lots of guys like those 5-gallon metal jerry cans, but one of those would block my turn signal/running light if I mounted it behind the sidecar wheel, and I simply don't like the looks of them mounted up front. Plus I kinda like the way No-Spill Jill handles that spout! :D

    Once I'd chosen the right bottle, then I paid a welder to fab up a cage for it from aluminum. Here's what I got--

    [​IMG]


    I mounted it with four 6mm stainless bolts, with body washers and nylock nuts inside the trunk, and 1/8" rubber grommets on the bolts so that the cage would not be rubbing the sidecar body constantly. Also so dust and dirt could flow past instead of building up. Here's what it looks like--

    [​IMG]


    It's a tight fit and the bottle stays in place OK, but I added the two velcro straps just to make sure it doesn't move. I also had the welder add a padlock tab in the back so if I'm parked someplace where I think pilferage might be a concern, I can padlock the bottle to the rack using a small chain.

    The only thing I'm not sure about is how well the bottle is going to deal with temperature changes. Extra pressure can be outgassed easily by pressing the green button on the spout, but I'm hoping it won't be something I have to think about.
  3. dholaday

    dholaday Been here awhile

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    DRONE:

    Nice looking. What did you put inside the trunk wall to support the extra weight of the gas can? Elmer added more fiberglass mats to his setup. [picture is in post #77 of his build thread, http://advrider.com/forums/showthread.php?t=439290&highlight=ingrid

    Wonder if the no-fill would fit in a peg-packer? My rig has one of the Best Rest models mounted on the frame between the tub and tug. Location makes it very easy to fill at the pump without having to move the rig or unmount the can.

    Do you know if No-Spill has/had the same leak problem on their 2.5 gal as on the 5 gal??

    "U.S. Consumer Product Safety Commission
    Release # 10-102
    Gas Cans Recalled by No-Spill; Containers Can Leak and Create Fire&#65279; Hazard
    Name of Product: No-Spill 5-gallon Gasoline Cans
    Units: About 7,500
    Manufacturer: No-Spill LLC, of Lenexa, Kan.
    Hazard: The gas containers can leak fuel at the black plastic collar where the spout connects to the can, posing fire and burn hazards to consumers".

    Thanks,
    Duncan
  4. DRONE

    DRONE Dog Chauffeur

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    Duncan--it only weighs 15 lbs when it's full so I'm not worried about the sidecar body being tough enough to hold it. I just used some 1.5" body washers and I'm calling it good. If the mounts start to show any signs of fatigue, I'll use some JB Weld to attach a couple of aluminum straps to the inside of the trunk. But I doubt it'll come to that.

    As for that recall, there was a small percentage of 5-gallon bottles manufactured during a 3-week period in the summer of 2009 that wouldn't seal right. 99.9% of No-Spill's bottles were not in the recall. As for my bottle, I filled it with gas then lay it on its side and stepped on it--no leak. Then I left it there overnight--no leak. Good enough for me!

    I don't think the No-Spill will fit a Peg Packer. The shape is different. I considered putting the bottle between the bike and the car but decided (1) the spout ends up too close to where Kirby likes to rest his head, (2) because I wear size 48 boots there would not be much room leftover for me to get my foot on and off the peg, (3) I'd have to remove the entire rack every time I wanted to adjust the lean-out or otherwise fiddle with the set-up, and (4) even though it doesn't weigh much, it's better to have the weight on the outside.

    Ya see, I actually did give this some thought before I did it! :lol3
  5. davebig

    davebig Another Angry Hun !

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    Nice rack your almost a Gearhead Ned !!!!! I would have considered mounting it slightly higher, and making it deeper hanging a second AGM or Qdyssey battery below it, ballast,amps and fuel whats not to like.DB
  6. XL-erate

    XL-erate Been here awhile

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    I do so enjoy your build there, DRONE! Obviously a product of deep thought, with cleverness and excellent workmanship in the mix the result will no doubt be stupendous!

    Worthy of note and not to be missed, every detail is addressed: even the oriental carpet laying beneath the hack of honor, lest lowly concrete and its vapor corrode. Not only that, but it's even carefully color- keyed to match and reflect the colors of the hack! Details.... :clap
  7. DRONE

    DRONE Dog Chauffeur

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    Didn't want to block the taillight/turn signal. Had to keep it low.


    Thanks, XL! Ya know, I paid $20 for that carpet at a garage sale. Beats the hell out of working on cement when yer wrenching on something. Check Craigslist--lots of cheap rugs out there -- then you too can do your wrenching in style! :evil
  8. XL-erate

    XL-erate Been here awhile

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    Thanks, great idea, but one minor drawback: garage? At best I scrounge up a scrap of plywood and call it luxury but at least I have plenty of room to work!
  9. Gentleman Adventurer

    Gentleman Adventurer Adventurer

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    Drone;

    Have you filled your tank from the No Spill Can yet?

    Just wondering if that short spout works as well as the video indicates?

    Thanks;

    Keith
  10. zipper421

    zipper421 Been here awhile

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    that looks nice
  11. DRONE

    DRONE Dog Chauffeur

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    I have, and it does work just like the video. Full disclosure, though, the spout on my can leaked when I first got it. I contacted No-Spill and they sent me a whole new spout assembly no questions asked. The replacement spout is tight as a drum.

    One thing I like about this product is if I break it or knock a hole in it, I can get a new one for $25 delivered. There's a ton of things on my rig that cost a lot more than that to fix or replace!
  12. DRONE

    DRONE Dog Chauffeur

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    Lost the brakes on the rear and the car. Air in the lines. First I tried a vacuum-style bleed and flowed a lot of fluid through both lines but no joy. Then I tried a reverse bleed. I have one of those reverse bleed kits from Griots Garage and it works well, but no matter how much fluid I pushed I still had air.

    Finally found success the old-fashioned way. My bike has two identical master cylinders mounted side-by-side, one for the rear and one for the sidecar. The master cylinders are activated by the brake pedal through two connecting rods. I disconnected the one rod, then bled the brakes using the brake pedal traditional way. Then I disconnected that rod and connected the other one, and did it again. That was all it took!

    Also want to tip my hat to Jay Giese at DMC who suggested that perhaps new air was getting into the system during the process by leaking past the threads in the brake bleeding nipples. Entirely plausible. So I greased those threads to seal them before I started on my third attempt. I wonder if that was the problem all along?
  13. davebig

    davebig Another Angry Hun !

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    No it never stops, his thesis is possible, often one has to remove calipers tap on and turn over to get air moving.DB
  14. DRONE

    DRONE Dog Chauffeur

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    Oh, I shoulda mentioned--I had both calipers off. Tapped, banged, swore at, held them high and low, upside down and sideways. I even tried sucking both of them completely dry using the vacuum and then starting over. This was a multi-day hassle of a bleed that I kindly boiled down into two paragraphs so as not to make it sound as frustrating as it was. I'd never heard about greasing the threads before--that was a new trick for me. Plus I think maybe you have to disconnect them from each other and do them one at a time.

    Posted as a service announcement to others with the same setup as me. :D
  15. XL-erate

    XL-erate Been here awhile

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    Thanks for sharing that tip, DRONE!

    I installed Air Lift airbags to my truck front axle to help handle the weight after I swapped in a diesel. Had to custom install, none made for my old truck. Too long to explain but I have a persistent leak in both bags, brass fittings screwed into brass, because of how I installed them. Tried tightening 2 or 3 times but didn't want to go any tighter for fear I'd twist off the soft brass.

    Never even considered greasing the fittings! Probaly just what it needs to allow them to thread down deeper and seal off the leaks. Thanks!
  16. dholaday

    dholaday Been here awhile

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  17. YOUNZ

    YOUNZ Been here awhile

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    Rather than grease, why not teflon tape?:huh
  18. davebig

    davebig Another Angry Hun !

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    I believe he means its got a slight air leak while he was bleeding it without the bleeder real tight.DB
  19. Wylder

    Wylder Adventurer

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    Hey Drone, What type of switch are you using for your adjustable shock? Could I get a pic of its mounting location.
    Thanks Wylder
  20. XL-erate

    XL-erate Been here awhile

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    Yes, but it's already too tight, kind of a jam fit. Air bags were installed last which meant that alignment of mounting holes was real difficult, unless I wanted to remove engine and motor mount pieces. Brass fittings rub against sides of holes going through motor mounts, messing up alignment with threaded holes in bags.

    Some kind of lubricant may help it thread down tighter is what I'm thinking.