Up and Riding! Building a new rig for my BMW 1200 GS Adventure

[Lew]

Whats happening Keith?

[2bfree]

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!  

[woody1]

What size and wall thickness square tubing are you using ?

[2bfree]

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!  

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.  

[ClimbingTurtle]

Damn, but that is fine!!

 

[Vis Arend]

Dig your new chassis and swingarm.   

Is there a brake system for the rig in your future plans?

[2bfree]

Dig your new chassis and swingarm.  

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.  

Its just sooooooooo good to be riding a rig again!  

[Vis Arend]

Dig your new chassis and swingarm.   

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. 

Its just sooooooooo good to be riding a rig again! 

 

Know the feeling.  So glad for your sake that everything is slowly but surely getting there.  Stay positive and stick it out.   

[woody1]

What size and wall thickness square tubing are you using ?

Just curious to know.

[2bfree]

What size and wall thickness square tubing are you using ?

Just curious to know.

38 mm x 3 mm

[woody1]

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. 

[2bfree]

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. 

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.

[woody1]

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.

[2bfree]

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.

[woody1]

Thanks, Now I am happy.... happier. 
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

[woody1]

Sorry man... one more.  Why did you opt for an adjustable bar on the back ?

[woody1]

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. 

[2bfree]

Thanks, Now I am happy.... happier. 
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.

[stevo]

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.  

[Mev Vis Arend]

Thanks, Now I am happy.... happier. 
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.    I merely allow him to ride it.