Second version of the Expedition hack.....mod update...update of the update

When we were still racing and building our own wings ( hate wings on sprint cars but ya gotta do what ya gotta do sometimes) the cleco fasteners were worth every penny . Great item for sure.

Is the base of the actuator arm pivot mounted straight onto the plate on the step, or is there bracing underneath?

Also could I suggest building a bumpstop from the chassis to above the swingarm so that any failures in the linkages or actuator doesn't allow the chassis of the sidecar to hit the ground and dig in. This is actually something I would like to see become more widespread from a safety perspective.

Yes there is a brace that runs longitudinal under there. Also (it's not yet in place) I lock the lever arm in the "highway" position in case the actuator fails. I do like your idea of a bump stop......last year I had the misfortune of my first attempt of a leveling system break on me.....locked the hack wheel and slid me into the ditch....was only doing a few MPH when it happened, but was quite the thrill. This system is ten timed beefier so I'm not worried of the same type of failure.....but the bump stop would add extra safety.

Ha! We have something in common then.
Mine did the sled conversion last year as well.
80kph or 50mph on dirt was an interesting experience.

I'm betting interesting experience dosen't even come close to describing the magnitude of the pucker factor you experienced! Had I been traveling at that speed when it happened, well, lets say it wouldn't have been a pretty picture.

Moving right along.....still putting the finishing touches on the rig. used a couple of mid sixties VW tail lights to build a rear stop / turn signal on the hack fender. Chopped two in half and used the out sides of each to make one unit that had enough material to scribe fit it to the fender. A bit of tack welding and bondo and there you go!

Very tidy.

The sled moments turned out after the initial shock, to be not so dramatic.
Corrogations got the better of a poor design decision.
But nothing dug in to cause loss of control.
It could have easily I suppose.
With the help of a heavy tie down strap I was able to ride it home.
Suspension Mk5 is much better.

Good to know it wasn't as bad as I was thinking.....Just a small adrenaline moment to tell you to work on your engineering skills. Had my little faux pas happened in another place with higher speeds, my wife would have been claiming a substantial benefit for my worldly departure.

Yes thankfully the wife was not involved.
Nor insurance companies.

I agree!!

Yeah my first one completely failed. Like yours, after a few miles it would slowly sink and I would have to give it a bump or two- Then it just wouldn't hold at all. The goofy clutch at the bottom just wouldn't hold. The up grade has been rock solid ever since.. Our Princess Auto, kinda like your Harbour Freight, I think, is where I got the replacement, wasn't expensive.

Hi Brian.....yup quite the pain in the rump.....I'm working on a locking system that can be engaged from the saddle.....not sure what just yet....but I'll get there!

Reworked the lever arm for the leveling system. Moved the linear actuator towards the front and changed a few things....have a look.

That top shock arm is stylish! Nice work.

Thanks! I hope to go brutalize it in Death Valley early next spring....I'm hoping it will hold up.

It will likely hold up fine, I'd be more concerned if you will hold up!

Darn good point! Forty five years ago it wouldn't have been a problem.....nowadays....odds are in the bikes favor!

Just a thought but anyone who runs an actuator on extended trips may want to consider building a solid or even a manual adjustable piece to replace the actuator as a simple 'insurance policy'.... Not agaist actuators but if one decides to go on strike far away from home it can be a bad 'remember the time story'. .

Always reckoned an old fashioned lever arm would work just fine.
Seriously.

Couldn't agree more Claude, I am working on a locking mechanism for it for highway travel. I couldn't afford one of those fancy pants acuators that lock when not juiced up. I do believe they operate with worm drive gears.