Wild Dog Adventure Riding

General => General Bike Related Banter => Sidecars => Topic started by: 2bfree on October 03, 2015, 05:44:43 pm

Title: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 03, 2015, 05:44:43 pm
I couldn't help myself. I've loved riding my faithful BMW 1200 GS Adventure around solo ... but I reeeeaally miss riding with my doggy and carrying all my camping equipment without the worry of overloading my bike.

I'm busy designing and building a new rig from scratch.
Title: Re: I couldn't help myself
Post by: woody1 on October 03, 2015, 06:41:31 pm
 :ricky:
Title: Re: I couldn't help myself
Post by: Mev Vis Arend on October 03, 2015, 08:29:04 pm
 :sip:
Title: Re: I couldn't help myself
Post by: Vis Arend on October 03, 2015, 08:39:39 pm
Good luck and all of the best with your new project.   :thumleft:  :thumleft:  Looking forward to see the end result.

For interest sake, will the fibreglass body hold up in the ruff stuff, or do you have a plan up your sleeve?    :patch:   :peepwall:
Title: Re: I couldn't help myself
Post by: Harry the Buffalo on October 03, 2015, 10:17:03 pm
 :happy1:
Title: Re: I couldn't help myself
Post by: Gérrard on October 04, 2015, 06:38:41 am
Welcome back Kieth  :thumleft:
Title: Re: I couldn't help myself
Post by: 2bfree on October 04, 2015, 08:35:53 am
Welcome back Kieth  :thumleft:
Cheers Jupiter.  :thumleft:
Title: Re: I couldn't help myself
Post by: 2bfree on October 04, 2015, 08:41:05 am
Good luck and all of the best with your new project.   :thumleft:  :thumleft:  Looking forward to see the end result.

For interest sake, will the fibreglass body hold up in the ruff stuff, or do you have a plan up your sleeve?    :patch:   :peepwall:
We'll have to see... doing it myself now with all the experience I've gathered from my riding and watching awesome adventures like yours, I can reinforce certain areas of the body where I've seen weaknesses, no more welding means no more stress on welding edges which can only be a good thing, the base of my two part mold is going to be very strong to withstand any vibrations, knocks and flexing.
Title: Re: I couldn't help myself
Post by: ktmmer on October 04, 2015, 09:49:03 am
Looks good, a few hours of work has gone in there!  :thumleft:
Title: Re: I couldn't help myself
Post by: 1ougat on October 04, 2015, 01:54:01 pm
 :thumleft:
Title: Re: I couldn't help myself
Post by: Vis Arend on October 04, 2015, 07:26:32 pm
Good luck and all of the best with your new project.   :thumleft:  :thumleft:  Looking forward to see the end result.

For interest sake, will the fibreglass body hold up in the ruff stuff, or do you have a plan up your sleeve?    :patch:   :peepwall:
We'll have to see... doing it myself now with all the experience I've gathered from my riding and watching awesome adventures like yours, I can reinforce certain areas of the body where I've seen weaknesses, no more welding means no more stress on welding edges which can only be a good thing, the base of my two part mold is going to be very strong to withstand any vibrations, knocks and flexing.

 :thumleft:  :thumleft:  Knowing you your heart and soul will go into this project.   :deal:
Title: Re: I couldn't help myself
Post by: Xchallenge on October 04, 2015, 08:45:47 pm
 :laughing4:
Title: Re:
Post by: jacquesman on October 05, 2015, 06:35:05 am
Will the suspension on it be able to lean and tilt around the corners?

Sent from my SM-P555 using Tapatalk
Title: Re: I couldn't help myself
Post by: Wooly Bugger on October 05, 2015, 07:13:21 am
 :thumleft: at least it won't sink.
Title: Re: I couldn't help myself
Post by: Xchallenge on October 05, 2015, 07:16:38 am
If you got some Reindeer and a red and white velvet suit, you could fool the kids into thinking you are Santa Claus!
Title: Re: I couldn't help myself
Post by: ClimbingTurtle on October 05, 2015, 07:55:39 am
It must be a sign.....

We are leaving on a 24-day trip to Namibia next week - by car, because of the game reserves. My wife was muttering yesterday that she thinks that we made a mistake, and we should be going on the GSA..... I brought up the subject of a SideCar...... A little while later, after leaving the thought alone, I was asked - "Where do you get a sidecar, how much...?"

The seed is planted, so I follow your project progress with great interest!!

 :thumleft:
Title: Re: I couldn't help myself
Post by: Vis Arend on October 05, 2015, 08:03:46 am
It must be a sign.....

We are leaving on a 24-day trip to Namibia next week - by car, because of the game reserves. My wife was muttering yesterday that she thinks that we made a mistake, and we should be going on the GSA..... I brought up the subject of a SideCar...... A little while later, after leaving the thought alone, I was asked - "Where do you get a sidecar, how much...?"

The seed is planted, so I follow your project progress with great interest!!

 :thumleft:

 :biggrin:  Mine started more or less the same way.  Now the wife is hooked.    :thumleft: 
Title: Re: I couldn't help myself
Post by: Wooly Bugger on October 05, 2015, 08:14:38 am
It must be a sign.....

We are leaving on a 24-day trip to Namibia next week - by car, because of the game reserves. My wife was muttering yesterday that she thinks that we made a mistake, and we should be going on the GSA..... I brought up the subject of a SideCar...... A little while later, after leaving the thought alone, I was asked - "Where do you get a sidecar, how much...?"

The seed is planted, so I follow your project progress with great interest!!

 :thumleft:

I like the way you think.
Title: Re: I couldn't help myself
Post by: Lew on October 05, 2015, 10:17:23 am
Nice to see you back buddy.Will follow this one.Hope you are doing well.
Title: Re: I couldn't help myself
Post by: dirtyXT on October 05, 2015, 10:19:35 am
 :sip:
Title: Re: I couldn't help myself
Post by: Sláinte Mhaith on October 05, 2015, 10:30:09 am
 :peepwall:
Title: Re: I couldn't help myself
Post by: 2bfree on October 05, 2015, 05:59:09 pm
Getting there... The hand crafted 'plug' almost ready for the fibreglass mold to be produced.
Title: Re: I couldn't help myself
Post by: 2bfree on October 05, 2015, 06:01:47 pm
Looks good, a few hours of work has gone in there!  :thumleft:
You better believe it... 2 weeks solid and I scrapped a weeks work and materials to start all over again!  :imaposer:
Title: Re:
Post by: 2bfree on October 05, 2015, 06:03:02 pm
Will the suspension on it be able to lean and tilt around the corners?

Sent from my SM-P555 using Tapatalk
Nope...
Title: Re: I couldn't help myself
Post by: 2bfree on October 05, 2015, 06:04:14 pm
It must be a sign.....

We are leaving on a 24-day trip to Namibia next week - by car, because of the game reserves. My wife was muttering yesterday that she thinks that we made a mistake, and we should be going on the GSA..... I brought up the subject of a SideCar...... A little while later, after leaving the thought alone, I was asked - "Where do you get a sidecar, how much...?"

The seed is planted, so I follow your project progress with great interest!!

 :thumleft:
Cheers... these are the kind of trips I'm building my new rig for.  :thumleft:
Title: Re: I couldn't help myself
Post by: 2bfree on October 05, 2015, 06:05:33 pm
Nice to see you back buddy.Will follow this one.Hope you are doing well.
Cheers Lew... hope you and yours are doing well.  :thumleft:
Title: Re: I couldn't help myself
Post by: Herklaas on October 05, 2015, 06:12:28 pm
 :sip: Waiting!!
Title: Re: I couldn't help myself... How to build a GS adventure sidecar.
Post by: 2bfree on October 08, 2015, 10:50:13 am
My new marine hatch 'boot' just arrived... I've used these before on my other rigs and they work fantastic. High quality, waterproof, vibration proof, lockable and very tough!
Title: Re: I couldn't help myself... How to build a GS adventure sidecar.
Post by: Xchallenge on October 08, 2015, 11:01:36 am
Gotta make that a cooler box for the beers...or a place to keep the children's prezies!

(http://preview.turbosquid.com/Preview/2014/07/04__00_00_09/santas_sleigh4.jpg8383e6e1-7c2e-4e1f-929d-1b141926824eHD.jpg)
Title: Re: I couldn't help myself... How to build a GS adventure sidecar.
Post by: ktmmer on October 09, 2015, 10:54:22 am
Are you making a top and bottom mould to be produced separately or will it be bolt together top and bottom. Then you lay it up through the cockpit?  Unbolt the mould to release the production.

Title: Re: I couldn't help myself... How to build a GS adventure sidecar.
Post by: 2bfree on October 09, 2015, 06:10:33 pm
Are you making a top and bottom mould to be produced separately or will it be bolt together top and bottom. Then you lay it up through the cockpit?  Unbolt the mould to release the production.


Yes, I'm going to attempt doing the mould in two halves... a reinforced base and then the top, laying up first the bottom then the top, then bolting them together and finishing off the 'cut' through the cockpit. I can see you've done this sort of thing before? Bit nervous about this as its the first time I've attempted it and the plug has taken me so many days (weeks) to get right and is still ongoing.  :thumleft:
 
Title: Re: I couldn't help myself... How to build a GS adventure sidecar.
Post by: VaalBaas on October 09, 2015, 06:26:46 pm
n Moet volg thread  :thumleft: :sip:
Title: Re: I couldn't help myself... How to build a GS adventure sidecar.
Post by: ktmmer on October 09, 2015, 08:54:17 pm
Are you making a top and bottom mould to be produced separately or will it be bolt together top and bottom. Then you lay it up through the cockpit?  Unbolt the mould to release the production.


Yes, I'm going to attempt doing the mould in two halves... a reinforced base and then the top, laying up first the bottom then the top, then bolting them together and finishing off the 'cut' through the cockpit. I can see you've done this sort of thing before? Bit nervous about this as its the first time I've attempted it and the plug has taken me so many days (weeks) to get right and is still ongoing.  :thumleft:
 


Remember, the finish of the product is as good as the finish on your plug !!  :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 13, 2015, 05:51:25 pm
Don't have a garage herein the forest where I live but a plank and some straps on the small patio work fine.  :laughing4:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 13, 2015, 05:53:26 pm
Fitted the subframe today... so center stand and bash plate off now.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 13, 2015, 05:55:15 pm
New Camil coil over shock arrived... expensive but worth it.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 13, 2015, 05:59:32 pm
One of the components just completed... the turnbuckle connector to bolt onto a modified telelever axle that I've designed, this axle rod replaces the BMW one. The telelever rod is already installed but when I remove it some time I'll take a pic. The turnbuckle is to adjust lean in and lean out of the bike.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 13, 2015, 06:01:12 pm
Now that my body has been designed and I have the dimensions I've started building the chassis.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: Harry the Buffalo on October 13, 2015, 06:07:28 pm
 :happy1: :happy1:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: stevo on October 13, 2015, 07:26:23 pm
 :thumleft: :thumleft: :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on October 13, 2015, 07:42:22 pm
Like the progress.   :thumleft:  :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: Humfree on October 14, 2015, 06:04:49 am
 :happy1:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: silvrav on October 14, 2015, 06:54:03 am
 :sip:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: TeeJay on October 14, 2015, 07:29:54 am
Great stuff....that looks like Knysna/Sedgefield forest? How do you get to live there? That's my dream - to live in a forest like that.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: Gérrard on October 14, 2015, 10:44:47 am
My 1150 is waiting  :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 15, 2015, 07:47:19 am
Great stuff....that looks like Knysna/Sedgefield forest? How do you get to live there? That's my dream - to live in a forest like that.
Yep, I live outside Rheenendal at the end of the 7 passes road, very beautiful, very private, very wild, very quiet... my cottage is the definitive 'cabin in the woods'. No garage of any kind so proof that anyone can build a good sidecar anywhere if they know what they're doing and have the passion.  :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 15, 2015, 07:49:12 am
My 1150 is waiting  :thumleft:
I hear you Jupiter... we'll talk. :ricky:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: gee on October 15, 2015, 08:12:24 am
looks good watching with anticipation to see how you going to connect it to the bike :sip:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: stevo on October 15, 2015, 08:29:13 am
Stunning cabin.
Title: Re: I couldn't help myself... How to build a GS adventure sidecar.
Post by: stevo on October 15, 2015, 08:45:43 am
My new marine hatch 'boot' just arrived... I've used these before on my other rigs and they work fantastic. High quality, waterproof, vibration proof, lockable and very tough!

Like this idea....
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: Black_Hawk on October 15, 2015, 08:54:08 am
Looking good. Can't wait to see the final result. Good luck with the build  :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: TeeJay on October 15, 2015, 09:12:44 am
Great stuff....that looks like Knysna/Sedgefield forest? How do you get to live there? That's my dream - to live in a forest like that.
Yep, I live outside Rheenendal at the end of the 7 passes road, very beautiful, very private, very wild, very quiet... my cottage is the definitive 'cabin in the woods'. No garage of any kind so proof that anyone can build a good sidecar anywhere if they know what they're doing and have the passion.  :thumleft:

Aaaahhhh thanks for the reply - absolutely beautiful. Don't want to hijack your thread but how does one even get to find places like this for sale - and I guess they are pricey?

Watching your project with interest. You are living the dream Sir!!!
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 15, 2015, 03:14:57 pm
Just back from a visit to a quality engineering works in nearby Knysna, basic chassis frame has been made up and heim joints securely tig welded into the square tubing... the subframe I've made up is a modification on the design I had on the previous 11 rigs made up, it's very strong!

It's raining today but will get stuck in tomorrow with more chassis / frame design work.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 15, 2015, 03:28:21 pm
Body is now ready for the fibreglass mold to be made up... the door has been cut with a gunnel fitting to the GS rear wheel profile, just to give you an idea of the time this all takes the windscreen mount which is drying for a coat of primer took me two full days to mold, sand etc

Holding thumbs... this weekend I'm starting the layering up of 6 layers of fibreglass for the two piece split mold, the last time I worked with fibreglass as a teenager my surfboard I was making caught fire and almost burnt down my dad's garage!  :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: JohnB on October 15, 2015, 03:43:04 pm
 :sip:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: stevo on October 15, 2015, 09:56:26 pm
 :thumleft: :thumleft: :thumleft: :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2StrokeDan on October 15, 2015, 10:15:54 pm
Beautiful home in a beautiful setting, handy as hell building things, come on you must have a drawback somewhere. Tell us...... :pot:

But honestly, great progress, and can I ask a question?

The frame that bolts under the bike's chassis seem to swivel independently from the side-car frame, or will the bike frame be bolted rigidly onto the side-car frame?
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2StrokeDan on October 15, 2015, 10:17:38 pm
Sorry, I just realized that you did say that the bike's lean-to towards or away from the rig can be adjusted with that turnbuckle, that explains the rose-joint under the bike.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 16, 2015, 06:00:38 am
Sorry, I just realized that you did say that the bike's lean-to towards or away from the rig can be adjusted with that turnbuckle, that explains the rose-joint under the bike.
Yep... and by screwing and locking the rose joints in and out front and rear you can adjust the tow in as well.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: GDA1 on October 16, 2015, 05:13:01 pm
nice work
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 19, 2015, 03:28:22 pm
Gel coat on!  :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: VaalBaas on October 19, 2015, 07:12:37 pm
Might be a stupid question, but how do you get the plug out.  ???  I know nothing about fibreglass, though practical, I don't get this out. Do you use the plug only once.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: frans1 on October 19, 2015, 08:47:05 pm
Shoe. 
You are brilliant!!

Like to watch your building of your rig to the end.

Thank you for sharing it with us.

I was thinking the other day, that this will be the only option for me to go for a ride on dirt if the legs are to old to keep the heavy bike upright.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: stevo on October 19, 2015, 11:45:12 pm
 :thumleft: looking good
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: Laban on October 20, 2015, 03:07:49 am



....man oh man...this is nice... :thumleft:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: TeeJay on October 20, 2015, 06:53:35 am
Is the body just made of fibreglass or do you use some carbon fibre and/or Kevlar as well? - or does that make it too expensive (and difficult to work with)?
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 20, 2015, 11:44:59 am
Might be a stupid question, but how do you get the plug out.  ???  I know nothing about fibreglass, though practical, I don't get this out. Do you use the plug only once.
I've split it bottom and top you'll see the white gelcoat on the top and the black on the bottom, once the top is done, flip it over and do the bottom, the spit is a piece of plastic I used, you lay up onto thisthen when you flip it over you take away the plastic and put a release agent on the lip and lay up on to this, when all done crack it open and there's your top and bottom molds, bolt them together again to lay up a new sidecar body.  :thumleft:

Its an absolutely ridiculous amount of work I've discovered... but I guess somebody has to do it.  :imaposer:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 20, 2015, 11:49:22 am
Shoe. 
You are brilliant!!

Like to watch your building of your rig to the end.

Thank you for sharing it with us.

I was thinking the other day, that this will be the only option for me to go for a ride on dirt if the legs are to old to keep the heavy bike upright.
Cheers!  :thumleft: By fitting one of these you can ride forever... and they're so much fun to share your passion with others... dogs, kids, girlfriends, wives... :ricky:
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on October 20, 2015, 11:50:38 am
Is the body just made of fibreglass or do you use some carbon fibre and/or Kevlar as well? - or does that make it too expensive (and difficult to work with)?
No, just fibreglass at this stage reinforced in the right places.
Title: Re: Building a new rig for my BMW 1200 GS Adventure
Post by: TeeJay on October 20, 2015, 12:29:41 pm
Is the body just made of fibreglass or do you use some carbon fibre and/or Kevlar as well? - or does that make it too expensive (and difficult to work with)?
No, just fibreglass at this stage reinforced in the right places.

 :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 07:11:43 am
Well... Six weeks of hard labour and finally my new body is ready!  :thumleft:

My initial attempt at building a mold onto the foam 'plug' I shaped and designed failed miserably so I started all over again and laid up my fibreglass over the thing and then broke out the foam after. I am truly amazed at the strength and weight of the final product, I reinforced the base with 5 layers of cloth and the upper half has 3 layers, breaking the foam and body filler out after setting was a real job and I had to go at chipping, grinding and hammering it out using a hammer and screwdriver smacking directly on the fibreglass... didn't even make a dent!!

Found some nice LED indicators and the marine hatch boot fits beautifully with lots of room to get in there, along with a new seat I am having made up I will be putting a fold down 3 mm aluminium backrest in that will also allow one to put larger things in and out of the boot if desired. The photos here are before I've done my final water papering on the flowcoat I put on to smooth it all out... from this I now have a professional boat builder who is going to build me a quality mold so I can make more of these bodies.
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: VaalBaas on November 04, 2015, 07:35:06 am
It is really looking good. :thumleft: Nice job
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: NeilV on November 04, 2015, 08:34:01 am
Really looks great, excellent job!  :thumleft:  :drif:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: stevo on November 04, 2015, 08:34:58 am
Looking really good..
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: T Rex on November 04, 2015, 08:42:20 am
This looks very nice  :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: chopperpilot on November 04, 2015, 08:46:15 am
Light and strong! Well done!


Sent from my iPad using Tapatalk
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Gérrard on November 04, 2015, 08:56:10 am
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on November 04, 2015, 09:02:09 am
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?

+1 
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 09:21:36 am
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
Yep... for all of the above reasons.  :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Gérrard on November 04, 2015, 09:28:36 am
OK Oom Chris, kry een van die, ek wil joune hę  :lol8:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 09:30:33 am
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
These bodies will be available as well as the drawings on CAD for my old body I used to make... people can make up their own minds about what they prefer.
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Gérrard on November 04, 2015, 09:44:23 am
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
I am busy drawing up all the sizes and measurements on a cad program for people to make the various components for these rigs themselves... proper DIY. They will also be able to source the components directly if they don't want to do it themselves. These bodies will be available as well as the drawings on CAD for my old body I used to make... people can make up their own minds about what they prefer.

 :thumleft: When you've done all the R&D and ready to market this one, please give me a price fitted to my bike.
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Knucklhead on November 04, 2015, 09:59:58 am
May I ask a very dof question.. can a sidecar be on any side? is there a regulation?

nice work by the way  :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: blainec on November 04, 2015, 10:06:03 am
 I would like the same info as Jupiter , I have a new 2015 GS 1200 Adventure that I want to keep as is , but based on your price for a complete rig I may sell one or two of my other bikes to get the right bike for your sidecar.

I have owned a Ural and the sidecar is fantastic but highway speed is a problem , I want to cruise at 120km/h but have a bike and sidecar that is safe and stable enough to overtake at say a max of 150 Km/h.

I like long distance touring but my job does not allow me to be away to long. With this in mind one of my favourite destinations is Namibia . I need a rig that I can do JHB to Uppington in one day on tar to allow me more time to travel and explore on dirt at a sedate speed.

I am watching this thread with interest and have buyers for two of my bikes.
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 10:07:35 am
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
I am busy drawing up all the sizes and measurements on a cad program for people to make the various components for these rigs themselves... proper DIY. They will also be able to source the components directly if they don't want to do it themselves. These bodies will be available as well as the drawings on CAD for my old body I used to make... people can make up their own minds about what they prefer.

 :thumleft: When you've done all the R&D and ready to market this one, please give me a price fitted to my bike.
Nothing will be as it was before Jupiter, I will not be marketing sidecars, forming a company or anything like that... My idea is that people can buy these as proper DIY kits and put them together themselves in their garage both locally and abroad. I now live on a farm in the 7 Passes and occasionally, as a personal favour, I will put one together for someone in my workshop. When I'm finished this rig (which has been sold already to a guy in Armenia coming to South Africa) I will give you a call and we can get together for a beer and a chat on my farm.  :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Gérrard on November 04, 2015, 10:09:42 am
May I ask a very dof question.. can a sidecar be on any side? is there a regulation?

nice work by the way  :thumleft:

Yes its a dof question. The side car MUST be on the left for when your wife passes you the coffee.

Your right hand  is holding the throttle  :lol8:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Gérrard on November 04, 2015, 10:10:52 am
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
I am busy drawing up all the sizes and measurements on a cad program for people to make the various components for these rigs themselves... proper DIY. They will also be able to source the components directly if they don't want to do it themselves. These bodies will be available as well as the drawings on CAD for my old body I used to make... people can make up their own minds about what they prefer.

 :thumleft: When you've done all the R&D and ready to market this one, please give me a price fitted to my bike.
Nothing will be as it was before Jupiter, I will not be marketing sidecars, forming a company or anything like that... I sell the plans and I provide certain components to make it easier for people to put these together themselves both locally and abroad. I now live on a farm in the 7 Passes and occasionally, as a personal favour, I will put one together for someone in my workshop. When I'm finished this rig (which has been sold already to a guy in Armenia coming to South Africa) I will give you a call and we can get together for a beer and a chat on my farm.  :thumleft:

 :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 10:11:34 am
May I ask a very dof question.. can a sidecar be on any side? is there a regulation?

nice work by the way  :thumleft:
Here in South Africa, as well as the UK, Australia, Japan etc they are mounted on the left hand side, this is the regulation. Be a bit scary for your passenger too if they had oncoming traffic coming at them all the time.  :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: LukasB9 on November 04, 2015, 10:12:57 am
Loads of work, well done!
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 04, 2015, 10:22:11 am
Now how about the fittings on a Super Tenere.... PLEASE !!!! :ricky:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Knucklhead on November 04, 2015, 10:25:27 am
May I ask a very dof question.. can a sidecar be on any side? is there a regulation?

nice work by the way  :thumleft:

Yes its a dof question. The side car MUST be on the left for when your wife passes you the coffee.

Your right hand  is holding the throttle  :lol8:

ou grapgat  :biggrin:

PM me jou roete vir slumdogs asb..
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 04, 2015, 10:34:15 am
If you need a S-10 to make the fitting.. I have time, I have a S-10 and I will camp on you lawn for a few days so that you can make this thing up for us okes with the Yamaha's

I can also bring BEER !! :imaposer:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Gérrard on November 04, 2015, 10:35:54 am
If you need a S-10 to make the fitting.. I have time, I have a S-10 and I will camp on you lawn for a few days so that you can make this thing up for us okes with the Yamaha's

I can also bring BEER !! :imaposer:

Hey, klim in die ry in  :deal:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 04, 2015, 10:48:20 am
Ek soek net die FRAME man... sommer tjop tjop vir die expert man doer in die bos.

 Ek het 'n idee van wat ek wil doen met my karretjie...sal jou later vertel.
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: VaalBaas on November 04, 2015, 10:51:10 am
.....een van daai 200l olie dromme :peepwall: :pot:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 04, 2015, 10:51:45 am
Yip.. Chromed  :imaposer:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Laban on November 04, 2015, 11:37:09 am
OK Oom Chris, kry een van die, ek wil joune hę  :lol8:

...nie so maklik nie Jup...myne het ge-jel met my...ek's 'n happy chappy... ;)
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 11:39:02 am
If you need a S-10 to make the fitting.. I have time, I have a S-10 and I will camp on you lawn for a few days so that you can make this thing up for us okes with the Yamaha's

I can also bring BEER !! :imaposer:
Every time I see a Super Tenere I take a look... in many ways its a lot easier because of the frame you have on it. I'm moving onto the farm middle of this month, let me just settle in and then come for a visit, a few modifications here and there to my chassis and I'm sure it can be done. Cheers.
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 11:47:18 am
I would like the same info as Jupiter , I have a new 2015 GS 1200 Adventure that I want to keep as is , but based on your price for a complete rig I may sell one or two of my other bikes to get the right bike for your sidecar.

I have owned a Ural and the sidecar is fantastic but highway speed is a problem , I want to cruise at 120km/h but have a bike and sidecar that is safe and stable enough to overtake at say a max of 150 Km/h.

I like long distance touring but my job does not allow me to be away to long. With this in mind one of my favourite destinations is Namibia . I need a rig that I can do JHB to Uppington in one day on tar to allow me more time to travel and explore on dirt at a sedate speed.

I am watching this thread with interest and have buyers for two of my bikes.
Hence the reason I'm going for a much lighter and streamlined body type this time, I've ridden twice from Sedgefield to Upington with my previous sidecar to lead safaris in the Kalahari, both times in a day - 950km... 200km of it dirt. Never really felt the need to go over 120km / h and the dirt / gravel is a breeze with a sidecar attached. Will let you know when I've tested my new rig properly.  :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 04, 2015, 12:37:55 pm
If you need a S-10 to make the fitting.. I have time, I have a S-10 and I will camp on you lawn for a few days so that you can make this thing up for us okes with the Yamaha's

I can also bring BEER !! :imaposer:
Every time I see a Super Tenere I take a look... in many ways its a lot easier because of the frame you have on it. I'm moving onto the farm middle of this month, let me just settle in and then come for a visit, a few modifications here and there to my chassis and I'm sure it can be done. Cheers.

I am taking you up on this and I am sure Visared Louis will be AS pleased as I am when we can get this on our bikes. :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on November 04, 2015, 01:36:38 pm
If you need a S-10 to make the fitting.. I have time, I have a S-10 and I will camp on you lawn for a few days so that you can make this thing up for us okes with the Yamaha's

I can also bring BEER !! :imaposer:
Every time I see a Super Tenere I take a look... in many ways its a lot easier because of the frame you have on it. I'm moving onto the farm middle of this month, let me just settle in and then come for a visit, a few modifications here and there to my chassis and I'm sure it can be done. Cheers.

I am taking you up on this and I am sure Visared Louis will be AS pleased as I am when we can get this on our bikes. :thumleft:

 :peepwall:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Man from Nam on November 04, 2015, 01:37:03 pm
Count me in for a S10 sidecar :thumleft:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 04, 2015, 01:41:10 pm
Nou ja NOU gaan ons almal sidecarre ry...want ons is mos oumense...  :peepwall:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Man from Nam on November 04, 2015, 02:12:05 pm
Dis nie ons wat oud is nie dis die vrouens :pot:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 04, 2015, 02:18:40 pm
Ja hulle is bang as ons omval GEBEUR daar dinge in die bos... :peepwall: :imaposer:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Man from Nam on November 04, 2015, 02:20:01 pm
Ek koes solank :peepwall:
Na ek gesien het hoe lekker die Visarende laas hier getoer het met hulle karretjie het ek nie 'n keuse nie, selfs 'n yskas in die karrejie
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on November 04, 2015, 02:25:32 pm
I would like the same info as Jupiter , I have a new 2015 GS 1200 Adventure that I want to keep as is , but based on your price for a complete rig I may sell one or two of my other bikes to get the right bike for your sidecar.

I have owned a Ural and the sidecar is fantastic but highway speed is a problem , I want to cruise at 120km/h but have a bike and sidecar that is safe and stable enough to overtake at say a max of 150 Km/h.

I like long distance touring but my job does not allow me to be away to long. With this in mind one of my favourite destinations is Namibia . I need a rig that I can do JHB to Uppington in one day on tar to allow me more time to travel and explore on dirt at a sedate speed.

I am watching this thread with interest and have buyers for two of my bikes.

These sidecars is comfi between 120 - 130.  Everything over that is an effort.  You will not be able to do long distances at a speed more than 130km/h, unless you super human.  Short burst at between 140-150km\h is possible but then you have to hold on for dear life.  I have reached 163km\h true speed (GPS) once, but you can hear and feel the bike battling.   My prefered speed is 125km\h.  The bike just feels happy at this speed.
But as 2bfree mentioned, they ride like a dream on gravel roads.  I have been to Nam with mine and we encountered some horrible sandy roads.  It was no problem for the rig, you just keep your cruising speed by slightly adjusting the throttle input.
I have found that I can travel further distances on gravel in a day with the rig (loaded) than with the bike, pillion and luggage.  But once again, I found that traveling on gravel between 80-100km\h was the best.  At this speed you can cruise all day long and enjoy the scenery and wildlife.  Yes, and you can also drink a cuppa (or something cold) at this speed.  You must just have a trained monkey.   I am a smoker, and at times I smoke on the go.    
      
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on November 04, 2015, 02:27:35 pm
Ek koes solank :peepwall:
Na ek gesien het hoe lekker die Visarende laas hier getoer het met hulle karretjie het ek nie 'n keuse nie, selfs 'n yskas in die karrejie

Yes ou mater, hoop dit gaan goed.   :thumleft:  :thumleft:

Yip, daai yskas was 'n lifesaver.  Altyd koue drinkgoed gehad en genoeg ys vir die dop.     :biggrin:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 04, 2015, 02:36:36 pm
I would like the same info as Jupiter , I have a new 2015 GS 1200 Adventure that I want to keep as is , but based on your price for a complete rig I may sell one or two of my other bikes to get the right bike for your sidecar.

I have owned a Ural and the sidecar is fantastic but highway speed is a problem , I want to cruise at 120km/h but have a bike and sidecar that is safe and stable enough to overtake at say a max of 150 Km/h.

I like long distance touring but my job does not allow me to be away to long. With this in mind one of my favourite destinations is Namibia . I need a rig that I can do JHB to Uppington in one day on tar to allow me more time to travel and explore on dirt at a sedate speed.

I am watching this thread with interest and have buyers for two of my bikes.

These sidecars is comfi between 120 - 130.  Everything over that is an effort.  You will not be able to do long distances at a speed more than 130km/h, unless you super human.  Short burst at between 140-150km\h is possible but then you have to hold on for dear life.  I have reached 163km\h true speed (GPS) once, but you can hear and feel the bike battling.   My prefered speed is 125km\h.  The bike just feels happy at this speed.
But as 2bfree mentioned, they ride like a dream on gravel roads.  I have been to Nam with mine and we encountered some horrible sandy roads.  It was no problem for the rig, you just keep your cruising speed by slightly adjusting the throttle input.
I have found that I can travel further distances on gravel in a day with the rig (loaded) than with the bike, pillion and luggage.  But once again, I found that traveling on gravel between 80-100km\h was the best.  At this speed you can cruise all day long and enjoy the scenery and wildlife.  Yes, and you can also drink a cuppa (or something cold) at this speed.  You must just have a trained monkey.   I am a smoker, and at times I smoke on the go.    
      
Ha! I know that one Louis... on the long flat sections like on the backroads through Veneektepan I always did the same, helmet off, put her in 4th gear for powering through the sandy sections, feet up and have a smoke or chew on some biltong at 70 km/h... try doing this on the dirt solo. This is when these rigs come into their own and you just can't stop smiling!  :ricky:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on November 04, 2015, 03:33:42 pm
This is when these rigs come into their own and you just can't stop smiling!  :ricky:

  :thumleft:  :biggrin:  :biggrin:  :biggrin:
Title: Re: Its almost ready! Building a new rig for my BMW 1200 GS Adventure
Post by: frans1 on November 04, 2015, 05:43:43 pm
Its really nice and I know its hard work, but preferred the shape and ergonomics of your previous one.

Why did you change to Glass fibre ? Ease of construction, cost, weight, weight to strength, aesthetics ?
I am busy drawing up all the sizes and measurements on a cad program for people to make the various components for these rigs themselves... proper DIY. They will also be able to source the components directly if they don't want to do it themselves. These bodies will be available as well as the drawings on CAD for my old body I used to make... people can make up their own minds about what they prefer.

 :thumleft: When you've done all the R&D and ready to market this one, please give me a price fitted to my bike.

2bfree please the same for me.  Just not before the end of 2015 for me :)  2016 will be better for the moelas
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 25, 2015, 04:35:34 pm
Just back from the engineers and they've done a fantastic job on my new raised chassis... a whole 100mm higher ground clearance than on my previous models, we now have 300 mm ground clearance under the tub, a true dual sport rig! Hoping to put the whole thing together for the first bit of gravel riding this weekend, bullbar, lockable luggage rack / fold out table, polycarb windscreen etc on the new body all complete and ready to GO!  :ricky:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: VaalBaas on November 25, 2015, 04:46:15 pm
Ek voel die excitment opbou. Laat kom daai pics. Dit is 'n lekker thread om te volg :thumleft:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: jangys on November 25, 2015, 05:06:23 pm
... :thumleft: :thumleft: :ricky: :ricky:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: 1ougat on November 25, 2015, 05:06:45 pm
 :thumleft:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on November 25, 2015, 06:29:53 pm
I am glad it is getting there... I have spare leave that I need to take..... :imaposer: :peepwall:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on November 28, 2015, 11:48:29 am
I said I wouldn't do any branding on my new rig but I had to call it something... so I've decided to call them Smiling Wind sidecars... here is the sticker I've designed and had made up. My new frame is looking amazing, and it now has a new design, very strong swingarm suspension fitted.

I need to sell a few things first to pay for it and pick it up next week,  :imaposer: it's a VERY expensive business this developing and building a new (quality) sidecar.

But so worth it for the enjoyment of riding the thing!!  :ricky:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: VaalBaas on November 28, 2015, 12:06:33 pm
Great stuff,. It looks cool :thumleft: :thumleft:

Lyk my dinge gebeur oor naweke, so nou wag ons maar vir volgende naweek vir die foto update :biggrin:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: Laban on November 28, 2015, 12:28:19 pm


... :sip:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: Jag man on November 28, 2015, 03:41:12 pm
 :peepwall:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: Lew on December 08, 2015, 07:08:09 am
Whats happening Keith?
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 08, 2015, 07:39:32 am
Almost there Lew, almost there... ran out of funds so have had to sell a few things to get my new design chassis out from the engineers, a new swingarm system and an additional 100mm clearance cost more than I thought to develop and build as I had to scrap what I'd done and paid for previously and start all over again.

Anyways, tomorrow morning I'll be picking it up and I'll be fitting the new body and test riding it here on the dirt roads for the first time over the coming week. I'll post pics as soon as I get the chance... I can't wait, it's all looking amazing!  :thumleft:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on December 09, 2015, 11:28:30 am
What size and wall thickness square tubing are you using ?
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 10, 2015, 07:05:29 am
Well, at long last I fitted my new chassis yesterday, bolted the body on and took her for a 50km spin on the dirt on the 7 Passes... all I can say is WOW! The additional 100 mm ground clearance makes this into a completely different machine to my previous rigs, she stands taller, (same height as a Toyota Fortuner I noticed)  feels a lot more 'nimble' and just all around it gives you the feeling of a true off road adventure vehicle... no more worries about 'middle mannetjies', large rocks and I can't wait for some heavy rains for river crossings!  :ricky:

Every 'weakness' I saw in my previous rigs I've rectified, the ground clearance, a MUCH stronger swingarm attachment with brass bushings and a grease nipple to keep it all well lubricated, a longer swingarm in the rear with a pivot point near the shock to stop the wheel leaning like a beach buggy under load, a larger gap between the tyre and the shock to stop rocks getting wedged between, a much stronger wheel hub and bearing setup, a better engineered and more easily accessible telelever rod and lean in / lean out connector set up for easier removal of the rig for solo riding... etc etc

All in all, so far I'm extremely happy with the result... the body I am still working on, now that I can actually see it fitted on the rig I can now finalise the design idea I envisaged from the beginning. I really want to move away from the Ural look, I envisage a custom built body made for serious expedition riding combined with the ability to comfortably carry a passenger... and / or doggy.  :thumleft:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: ClimbingTurtle on December 10, 2015, 07:13:44 am
Damn, but that is fine!!

 :drif:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on December 10, 2015, 07:27:44 am
Dig your new chassis and swingarm.   :thumleft: :thumleft:

Is there a brake system for the rig in your future plans?
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 10, 2015, 07:31:41 am
Dig your new chassis and swingarm.   :thumleft: :thumleft:

Is there a brake system for the rig in your future plans?
Absolutely Louis... it's all about time and money though right now... I have time but I've run out of money.  :imaposer:

Its just sooooooooo good to be riding a rig again!  :ricky:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on December 10, 2015, 07:42:27 am
Dig your new chassis and swingarm.   :thumleft: :thumleft:

Is there a brake system for the rig in your future plans?
Absolutely Louis... it's all about time and money though right now though... I have time but I've run out of money.  :imaposer:

Its just sooooooooo good to be riding a rig again!  :ricky:

 :thumleft: :thumleft:

Know the feeling.  So glad for your sake that everything is slowly but surely getting there.  Stay positive and stick it out.   :thumleft:
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on December 10, 2015, 07:45:49 am
What size and wall thickness square tubing are you using ?

Just curious to know.
Title: Re: Counting down the days! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 10, 2015, 07:57:27 am
What size and wall thickness square tubing are you using ?

Just curious to know.
38 mm x 3 mm
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on December 10, 2015, 08:00:44 am
Thanks.  I thought 50 x 50 x 3 would be used for such a big rig.
Surprised it is only 38mm


I like the 3mm then you can WELD and TAP into it without problem.  :thumleft:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 10, 2015, 08:09:08 am
Thanks.  I thought 50 x 50 x 3 would be used for such a big rig.
Surprised it is only 38mm


I like the 3mm then you can WELD and TAP into it without problem.  :thumleft:
The wheel and the strong subframe takes most of the weight, the 'S' bend you see coming out from under the bike in the front to create the extra ground clearance is made from solid high tensile steel, a real piece of engineering to cut, shape, weld and 'sleeve' it into the tube.
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on December 10, 2015, 08:13:15 am
Thanks.  As I am no engineer and does not know how strong steel construction is.
 I thought that you should put some gussets between the UPRIGHT pieces for support.
Currently it is only the weld that keep it there.  Under stress will it not break easily there.

Tried to illustrate it with this picture where I think I would like to see extra support.

Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 10, 2015, 08:23:26 am
Thanks.  As I am no engineer and does not know how strong steel construction is.
 I thought that you should put some gussets between the UPRIGHT pieces for support.
Currently it is only the weld that keep it there.  Under stress will it not break easily there.

Tried to illustrate it with this picture where I think I would like to see extra support.


Well spotted, The shock absorber post is certainly going to get one but I wanted to fit the body first so I know how much space I have and where to position it. The 'A' frame is not really necessary but it wouldn't hurt to brace it.
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on December 10, 2015, 08:34:34 am
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on December 10, 2015, 08:36:27 am
Sorry man... one more.  Why did you opt for an adjustable bar on the back ?
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: woody1 on December 10, 2015, 08:43:29 am
Wait,  I think I know... Because the frame is pretty much fixed on the bike, you use this to adjust toe- in on the sidecar wheel.

Please tell me I am correct.  :imaposer:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 10, 2015, 08:53:36 am
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
In all honesty these are R 200 000 questions Woody... R 80 000 (so far) is what it just cost me to design, test and manufacture these components for this particular rig... add another R 120 000 'down the tube' for R&D and a year of testing for the previous rigs I made for guys like Louis.

The BMW telelever 'axle' I remove and replace with my own, the turnbuckles you can get from any decent bearing shop.
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: stevo on December 10, 2015, 09:01:33 am
Hi Keith

I think it looks stunning. I agree with Woody on the gussets, especially the upright post for the shock, you will need to transfer some of that movement back to the frame and support the weld. Simple explanation, but you will understand the meaning.

I do have a question though, your adjustable bar on the back, this pivots in an arc as the swingarm moves... is there enough movement in the rose joints used to compensate for this? A torsion bar will do the same, but allows for movement. Otherwise the bushing in the front of the swing arm will wear quickly...

Have you used a solid insert for the wheel axle where it joins and is welded to the swingarm end?

Otherwise, I like, simple straightforward and robust.  
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: Mev Vis Arend on December 10, 2015, 10:03:21 am
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
In all honesty these are R 200 000 questions Woody... R 80 000 (so far) is what it just cost me to design, test and manufacture these components for this particular rig... add another R 120 000 'down the tube' for R&D and a year of testing for the previous rigs I made for guys like Louis.

The BMW telelever 'axle' I remove and replace with my own, the turnbuckles you can get from any decent bearing shop.

Haaibo, that Karretjie was not made for Louis.   :o I merely allow him to ride it.  :pot:   
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 10, 2015, 10:17:41 am
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
In all honesty these are R 200 000 questions Woody... R 80 000 (so far) is what it just cost me to design, test and manufacture these components for this particular rig... add another R 120 000 'down the tube' for R&D and a year of testing for the previous rigs I made for guys like Louis.

The BMW telelever 'axle' I remove and replace with my own, the turnbuckles you can get from any decent bearing shop.

Haaibo, that Karretjie was not made for Louis.   :o I merely allow him to ride it.  :pot:   
Ha Ha!  :laughing4:  Lekker man Nannie... I don't differentiate between you two... Louis / Nannie and "Karretjie' you're one unique 'team' to me.  :imaposer:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: Mev Vis Arend on December 10, 2015, 11:22:10 am
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
In all honesty these are R 200 000 questions Woody... R 80 000 (so far) is what it just cost me to design, test and manufacture these components for this particular rig... add another R 120 000 'down the tube' for R&D and a year of testing for the previous rigs I made for guys like Louis.

The BMW telelever 'axle' I remove and replace with my own, the turnbuckles you can get from any decent bearing shop.

Haaibo, that Karretjie was not made for Louis.   :o I merely allow him to ride it.  :pot:   
Ha Ha!  :laughing4:  Lekker man Nannie... I don't differentiate between you two... Louis / Nannie and "Karretjie' you're one unique 'team' to me.  :imaposer:
Thanks, Now I am happy.... happier.  :imaposer:
Where does the A- Frame top bolt onto the bike?
Does it also go through the bike or is there a mounting point on the GS frame strong enough to handle the stress ?

Sorry for all the questions.  Where did you buy those turnbuckles ? What are they called ?  Are they S/ Steel ?

Thank's
In all honesty these are R 200 000 questions Woody... R 80 000 (so far) is what it just cost me to design, test and manufacture these components for this particular rig... add another R 120 000 'down the tube' for R&D and a year of testing for the previous rigs I made for guys like Louis.

The BMW telelever 'axle' I remove and replace with my own, the turnbuckles you can get from any decent bearing shop.

Haaibo, that Karretjie was not made for Louis.   :o I merely allow him to ride it.  :pot:   
Ha Ha!  :laughing4:  Lekker man Nannie... I don't differentiate between you two... Louis / Nannie and "Karretjie' you're one unique 'team' to me.  :imaposer:

Je, you know how to smear jam around my mouth, but I must admit, I caught myself a very nice oukie 30 something years ago.   It is not too difficult to like him.   :biggrin:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 14, 2015, 01:29:26 pm
Done and dusted!  :thumleft:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: Laban on December 14, 2015, 01:43:29 pm


... :thumleft:
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: Vis Arend on December 14, 2015, 04:01:17 pm
Very nice, some decent clearance you have there.   :thumleft:  :thumleft:  With the right tyre pressure that thing will float over the sand.   ;)
Title: Re: Up and Riding! Building a new rig for my BMW 1200 GS Adventure
Post by: 2bfree on December 14, 2015, 04:52:45 pm
Very nice, some decent clearance you have there.   :thumleft:  :thumleft:  With the right tyre pressure that thing will float over the sand.   ;)
I'm not sure what it is Louis but the whole thing just feels so much 'lighter' and more 'nimble' now. Like you're riding on top of everything now not 'in' it.  :thumleft: