I'm moving over from the renovation part of this forum to the sidecar part as we start building now!

I'm drawing som 3D on my spare time so the general idea is coming along nicely:

Design looks good now, you need a good 3D printer to do the hard work 

We've started welding up the single sided front suspension mount now;



Mockup


New saddle on the K1100! The old one was too high to ride the bike comfortable... Going to fit GSXR750 clipons soon too!

I'm curious to see how this turns out, as I love to see experimental and creative suspension concepts turn to reality, and also wondering what sort of Norge governmental inspection it'll have to be put through to be considered 'roadworthy'.

Cheers

Two Wheels Better wrote:I'm curious to see how this turns out, as I love to see experimental and creative suspension concepts turn to reality, and also wondering what sort of Norge governmental inspection it'll have to be put through to be considered 'roadworthy'.

Cheers

Govermental inspection yes... we do not plan to ask them to do one... the bike already has a license plate...   
Until last year all rebuilding was banned totally in the legal way... But as the frame we are using is a veteran this year, we can get it registered as a vetran in the condition it is when reviewed for getting veteran papers. Veteran is when the bike is over 30 years old in Norway, it's much cheaper to own and use! 
This is our third suspension build like this one, The designs are getting more and more radical!   
Got one more in our heads, Bimota lookalike, one control arm on each side of a car hub of a Smart car.

The front and rear wheels on this one too is going too be from a Smart car, if we just could get ahold of some...

New rims for the build ordered! I'm hopefully going to get them from the supplier today! 
Genius Darwin Gunmetal rims for a Smart Car.

More welding and fabrication pic's!
We do not have an advanced drilling machine: 

My dad TIG-welding the frame for the swingarm on the bike.

Tight fit:


Test fitting on the bike:

BMW car bushings for the swingarm mounts:

My dad was not satisfied with the saddle, so a new one was made:



With heat!



Templates for the combined engine/swingarm mounts:


The result!



Double steel thickness at the top mounts:




The engine frame mount for the swingarm is done! Close one though, the Argon bottle is empty...





Sidecar mount:

Once again, wow.
Wish I lived a bit closer to you guys.
 

Beautiful fabrication skills. 

  Respect, guys !

Keep us informed...
Jos.

My dad's been drawing abit:





The sidecar is going to be made out of strips of wood, fiberglass and epoxy, like we made theese kayak's some years ago!




Template for start of the wood building, in our wood shop:
¨


The crossover is where my knees are when sitting like we think we will...

Some more pictures of the wooden sidecar project!




It's going to be coated with fiberglass and epoxy, then smoothed out and painted red.

Bottom of the sidecar being produced in plywood this time:






Fiberglass and epoxy coating on the inside of the sidecar:


Starting to build the frame inside the sidecar, all pipes are stainless steel.






Some mockup of the control arms on  the old K100 engine:


Trying to get the right height:



General look test, before we start to fit it in correct


Turning out a new spacer for the rear wheel to fit the smart car wheel:


You can see the blueprint and drawings of how to turn it on the lathe on the side of the aluminium piece...


Lathe and cutter at dad's work place:



The new front end coming together nicely!


Cross to strengthen the construction and general fitment of the front wheel. The new front bearing mount is coming together too, but i do not have any pictures of that until tonight!


This will be enough turning action


Here is a picture my dad took of the K1100 on Crystal Rally this year:

1st May yesterday, it's a tradition to go on a motorbiktrip at 1st May here, but when i wake up I saw this from my window:


Some more front suspension build pictures:












One old GSXR shock will make do until we get a new one. The shock mount is moveable until we get it on all three wheels and we'll be able to drive it and figure out where to put the shock.












Steering and control arm done, now it's just the tie rods up to the lower fork bridges left! Gotta turn out some new aluminum rods to connect the two fork bridges too.








General setup, and the dog, Guzzi looking it all over!


Trying to figure out where to put the sidecar fork...

 Wow... you're making some progres here !
Thank's for the huge amount of pic's, keep 'm coming ! Love it... Great job   

Jos

Mathematics and mechanic calculations at school can be transferred a bit into building too, trying to figure out which way it's best to mount the shock on the sidecar.

Some pictures of the steering control arms setup:





It's made at the crooked angle to accomodate the travel of the wheel due to the constant changing angle on the hub. The rods are going to be chaged to stainless BMW E46 318IS stabilisator rods when we get some in the mail in near future!

As always: great to see you're progress !
Hope there is a change of weather in your region, so that you can get out of the shed every once and a while ?   

Cheers...
Jos

GTJos wrote:As always: great to see you're progress !
Hope there is a change of weather in your region, so that you can get out of the shed every once and a while ?   

Cheers...
Jos

My dad isn't that many days in the shed all things considered, I'm only home on the weekends, but it's mostly evenings that is spent in the garage!

Here's a video from now on sunday:

Some more pictures from earlier on in the build progress from my dads camera:
Pictures from the progress making the hack:
























Top half done, time for the bottom part!

mleikarnes wrote:

GTJos wrote:As always: great to see you're progress !
Hope there is a change of weather in your region, so that you can get out of the shed every once and a while ?   

Cheers...
Jos

My dad isn't that many days in the shed all things considered, I'm only home on the weekends, but it's mostly evenings that is spent in the garage!

Here's a video from now on sunday:

Ha ! A speedy ride in an astonishing scenery; still lots of snow I see ?!
Thank's; keep up the good work ! (Great to see the 'boat' growing from nothing to its present state. Good craftmanship, that's for sure !)

Jos

We've started fiddeling with the K again! My dad has made a new swingarm, the last one was too short to get the suspension geometry right. There was no room to move the lower spring mount around to get more suspension travel. 

The old swingarm and pipes for the new one.


New swingarm being mounting:






New and old swingarm, the new one looks more lean and is better made to accommodate better suspension




Ready for mounting of the hack!


Hack trial mounted!




Hack suspension:




I saw that i posted the reply in the wrong sidecar thread... so I'll repost it and build on some more pictures!

Making of a new fender on the sidecar, also in wood!




Cut down and epoxy'ed up!




A little sanding before a fast temporary paint job


A bit more sanding
https://lh6.googleusercontent.com/-tVYpGQf6T0Q/VKu77uflWtI/AAAAAAAB9wc/FbGvwWqo1CM/w1118-h629-no/DSC_1199.JPG

Temporary paintjob done! There is going to be some white stripes to!


Some may remember Donald Duck's 313 car? this seat/lid is made the same way as his backseat!


Don Rosa and Carl Barks knows how to make inspiration for sidecars!


Some of my dads other inspiration is these Formula 1 cars:
Ferrari 500 F2

Maserati 250F


Sidecar mounted once again!




New custom made brakelines from Venhill parts!


Close call with the rim!


Brake lines to the sidecar wheel, one caliper is hooked up to the front brake and one is hooked up to the rear brake.


Two times Kawasaki GPZ 750 rear calipers on the sidecar wheel.


Radiator and grille mounted, the fan is hooked up to the ignition.


Rear light on the sidecar mounted too, we need to find a white and orange LED light for the front...


Test ride!




Hit 1080p HD!

Veldig kult ! The sidecar too....

That's good. I've enjoyed reading this thread - there's some really interesting engineering going on there.

Impressive build and makes a very interesting read. Thanks for the posts.
In the end what made you decide how and where to mount the shock on the sidecar? It looks to be pretty much vertical?
Sean.