Sidecar Project

Hannigan Astro serial no. HFC880046

Order of Priority

Description of Modification/Repair

Date completed:

1.

Replace lock assemblies, 2 required, for trunk and for cockpit.

· Done 12/08/2003

2.

Correct bolt/nut washer for front cowl chain.

· Done 13/08/2003

3.

Epoxy main nuts for lock assemblies to prevent loosening.

· Done 13/08/2003

4.

Finish cleaning out remnants of bondo from interior of sidecar.

· Done 16/08/2003

5.

Strip out carpet and chair from sidecar.

· Done 16/08/2003

6.

Vacuum and clean interior.

· Done 16/08/2003

7.

Repaint interior of sidecar black.

· Done 22/08/2003

8.

Fabricate diamond plate step cover for sidecar.

· Material purchased 22/08/2003 - $35.18

· Done 26/08/2003

9.

Use black 55 watt halogen slimline running light for sidecar, mount to underside of fabricated diamond plate step.

· Done 27/08/2003

10.

Replace right exterior ‘truck’ running light with cleaner looking unit.

· Flush mount light purchased 28/08/2003

· Done 04/09/2003

11.

Remove frame mounted light hanger. No longer reqd.

· Done 12/09/2003

12.

Investigate new bucket seat out of a 2 door, needing recline/forward tilt feature from wrecking yard.

- Nissan 240sx bucket obtained out of wreckers – cost $57.50.
· Done 18/08/2003

- Fabricate new seat mount brackets
· Done 14/09/2003

· Done 17/09/2003

13

Check condition of sidecar shock assembly.

- Did have a little air remaining when Schrader valve tested.
· Done 18/08/2003

- Stock shock is reportedly a ‘jobber’ shock meant for a volkswagon.
- Showa air shock from a HD is a possible replacement source.
· Shock tested, holds an air charge, replacement not necessary

· Done 23/09/2003

14

Replace broken top window, take original to Oakville Glass and Mirror as a pattern.

- Checked at OGM for possibility of repair, 03/09/2003 – they are unable to handle this repair due to curvature of window.

· 1/8" plexiglass purchased from OGM 27/09/2003 to fabricate new window - $29.82

· Done 27/09/2003

15

Paint top roof window section for sidecar.

· Done 28/09/2003

16

Obtain new carpet - dark gray color to match 240sx bucket seat.
· Dark gray section purchased 22/08/2003 - $30.00

· Installed 06/10/2003

17

Investigate finding a chrome rim replacement.
· Supplier found through NAPA auto parts, rim ordered 03/10/2003, for $80.50 CDN.

· Received 07/10/2003

18

Check that tire size is compatible with clearance with suspension.
- currently has a 6.00R12 trailer tire on it.
- Reportedly a 145R12 is largest size that will fit.
- 6.00R12 converts to 155R12.
· Bridgestone 145R12 tire purchased 07/10/2003

· Installed 07/10/2003

19

Separate sidecar body from frame, store sidecar body at work, frame to be brought home.

· Done 16/10/2003

20

Dis-assemble sidecar braking system.

· Done 19/10/2003

21

Dis-assemble and check condition of sidecar master cylinder assembly. Pivot point seized, at very least.
· Caliper pistons un-seized 19/10/2003
· hydraulic brake fluid flushed and refilled 19/10/2003
- Master cylinder cover is corroded and perforated
· Replacement part unavailable, cover JB Welded and repainted 21/10/2003
- Mount needs to be stripped, sandblasted/cleaned and repainted.

· Done 22/10/2003

22

Fabricate linkage for sidecar brake system.
· Stainless steel 1/4" threaded rod, clevis joint, and rod end purchased from Brafasco $38.17 - 20/10/2003

- Find appropriate rear brake pedal.
· Suzuki GR650 shifter pedal located in spare parts, 20/10/2003

- Fabricate clamp-on brake pedal sub assembly for sidecar brake system.
· Done 21/10/2003

- Send off for welding to Bron machine shop
· Done 22/10/2003

- Design and fabricate rear brake pedal return spring method.
· Done 23/10/2003

· Completed 23/10/2003

23

Reassemble sidecar braking system.

· Done 23/10/2003

24

Get new attachment bolts to mount sidecar body to sidecar frame from Brofasco.

· Done 09/12/2003

25

Fabricate sidecar frame dolly to make movement and mounting more portable.

· Done 21/12/2003

26

Rear tire, motorcycle.

- Obtain core Bandit compatable rear wheel assembly for centerline car tire conversion from wrecking yard. Cost appx $400.00 CDN.
- Have converted at cost of $657.00 USD.

· 13/12/2003 - Obtained 1993 GSXR600 rear rim assembly from JC Motorsports with brake rotor, and sprocket hub for $350.00 CDN.
· 29/12/2003 - Sent to Harry Tarzian of HT Wheels in Pennsylvania to have conversion done, cost $930.00 CDN + $31.00 CDN for shipping.
· 04/02/2004 – Wheel assembly returned in converted condition.

- Will need replacement 5 bolt pattern 48 tooth sprocket ordered (same as RF600R)
· Ordered 24/01/2004 - Cost $62.99
· Received 28/01/2004

- Will need spacer fabricated to correct sprocket offset.
· 07/02/2004 - Fabricated sprocket spacer out of aluminum.
· 07/02/2004 - Installed wheel on motorcycle

· Done 07/02/2004

27

Reinstall stock chain guard on motorcycle.

· Done 07/02/2004

28

Replace plastic break-away screws for windshields/windows, 50 pcs appx reqd
- 15 pcs reqd top roof window
· Done 28/09/2003
- 21 pcs reqd main bubble
- 12 pcs reqd side windows
- 100 pcs each 10-24x3/4" nylon bolts and nuts ordered from Brafasco 13/08/2003 - Cost $27.81

Brafasco
1155 Appleby Line
Burlington, ON
905-335-8003
Order: ORD100073855 sales rep: Angelo
Received 19/08/2003

· Done 01/03/2004

29

Re-install stock mud-guard and related parts on motorcycle.
· Installed 07/03/2004

· Done 07/03/2004

30

Get three locking nuts for sidecar strut mounts.
· Purchased from Brafasco $10.82 - 11/03/2004

· Done 11/03/2004

31

Stereo Installation

JVC am/fm/cd radio deck.
· Purchased 22/09/2003 - $202.89

Fabricate right hand Stereo Console for radio/beverage holder, fiberglass construction.
· Mold form fabricated 06/09/2003
· Console fiberglassed, finished and access panels/hinges/radio mount completed 23/09/2003

Fabricate amplifier module enclosure, fitting behind wheel well in cargo space. Plastic/plexiglass/plywood construction.
· enclosure fabricated 20/09/2003

600 Watt Amplifier, for subwoofer, rewired and put into own enclosure
· Purchased 26/02/2004 $149.00
· Installed into amplifier module console 08/03/2004

Pioneer 80 watt 3-way speakers mounted into enclosure behind seat, wood construction.
· Speaker box fabricated 27/09/2003

Pioneer 100 watt 2-way speakers mounted into enclosure in front of seat, wood construction.
· Speaker box fabricated 25/02/2004

8" Subwoofer, mounted into enclosure behind seat, wood construction.
· Purchased 26/02/2004 $99.00
· Speaker box fabricated 14/03/2004

· Done 16/03/2004

32

Rewire interior of sidecar.

Provision wiring runs for interior light, exterior RHS running light, RHS switcheable driving light, brake/tail and turn signal light, and radio equipment.

· Molex connectors purchased from Spaunaur 07/02/2004 - $130.00
· Wiring harness fabricated 25/02/2004

· Wiring harness installed on sidecar and motorcycle 21/03/2004

· Done 21/03/2004

33

Mount hardware. http://www.dauntlessmotors.com/Mountinghdw_files/

- Essentially complete, for attachments to sidecar. Hardware needs sandblasting and repainting.
- Motorcycle attachments largely incomplete.

- Sidecar mount point measurements (sidecar frame):
·Top front to top rear – 22”
·Bottom front to bottom rear – 31”
·Top front to bottom front – 15”
·Top rear to bottom rear – 18”

- Motorcycle subframe measurements:
·Unladen measurement, rear floor to rear mount mid-rail, 8"
·laden measurement, rear floor to rear mount mid-rail. 6.75"
·Unladen measurement, front floor to front mount mid-rail, 8.5"
·laden measurement, front floor to front mount mid-rail, 8"
·Lower mount front to rear, 27.25"
·Front mounts top to bottom 15"

· 26/11/2003 - Ordered from Dauntless Motors
- 1 x 70° Boss, 1 x 70° clamp
- 1 x 45° Boss, 1 x 45° clamp
- 2 x Clevis weld on mount
- 2 x 5/8" male Hiem Joint
- 2 x Rod eyes- 2 x threaded insert sleeves for Rod eyes- all related bolt hardware

· 18/11/2003 - Order Received from Dauntless Motors, $308.00 USD incl shipping, plus $60.97 CDN import taxes.

Mount setup progress - 5 sub-assemblies total.

1 · Four point, three part (swingarm pivot mount assembly, engine mount assembly, and upper frame tube mount assembly) Subframe fabrication and welding started 28/10/2003.
· 06/01/2004 - Subframe fabrication and welding completed.

2 · Upper front mount using short strut.
- May require this strut to be chopped and shortened to fit and allow adjustability.

3 · Front lower mount, 90° parts from original Hannigan 90° strut.
· 31/12/2003 - disassembly, cutting and rejigging of 90° angles done, original Hannigan strut recycled for receiver tubing.
- Get rewelded by Bron machine shop.
· 24/03/2004 - Welded.

4 · Rear lower mount, refabricate 70° clamp and clevis mount to 90° angle, with hiem joint and clevis mount.
· 27/12/2003 - disassembly, cutting and rejigging of 90° angles done, original Hannigan strut recycled for receiver tubing.
- Get rewelded by Bron machine shop.
· 06/01/2004 - Welded.
- will require clamp and boss shafts to be cut down to correct length.

5 · Rear upper mount
- Sidecar frame, cut out fuel filler neck, and weld patch over top.
· 02/01/2004 - Fuel filter tube chopped from frame, patch and sleeve fabricated.
- Weld in place eye and sleeve in patched location, to relocate upper rear strut mounting position farther back on sidecar frame.
· 07/01/2004 - Welded.
- Use long strut, might require lengthening of threading sleeve to fit.
- use frame bracket, welded into motorcycle subframe, near mount location of exhaust canister.
· 03/04/2004 - Welded.

· Done 24/03/2004

34

Inspect and repack bearings on sidecar swingarm and axle.
· Hub assembly disassembled, bearings inspect ok - 22/03/2004
· Hub center and bearing carrier painted black - 24/03/2004

· Done 27/03/2004

35

Remove rust on sidecar frame, and tremclad.

· Done 29/03/2004

36

Paint subframe, struts and various fittings tremclad black, two coats minimum. No time remaining for powdercoating.

· Done 31/03/2004

37

Front tire, motorcycle, replace with 130R70/17 bias-ply rear tire, mounted backwards.
· Ordered Avon AM52 from Burlington Cycle City, $129.95 - 24/03/2004
· Installed - 02/04/2004

· Done 02/04/2004

38

Reassemble sidecar body to frame.

· Done 03/04/2004

39

Steering Dampner
- Required to calm front end speed wobble characteristics at low speed.

· Shindy Daytona Dampner and bracket ordered 08/04/2004 - $352.00 CDN

· bracket Fabricated and Dampner installed 17/04/2004

· Done 17/04/2004

40

Fox Rear Shock, motorcycle.
- Present 550 lb spring overwhelmed by combined weight of motorcycle, sidecar and operator.

· Replacement 800 lb spring ordered 09/04/2004 - $95.00 USD.
· Spring replaced 19/04/2004 - $42.70 CDN service cost to remove and replace spring on shock.

· Tendancy for rig to body roll, squat, and general handling greatly improved by uprated spring, only thing that could improve situation would be a swaybar linkage setup.

· Done 19/04/2004

41

Sidecar body molding trim
- Old trim was lifting and shrinking off the body of the sidecar, had to be replaced.

· Trim ordered from 3M trimline 08/07/2004, $92.00 CDN.

· Installed 14/07/2004

42

Hatch hydraulic rams
- Replaced front hatch chain with a hydraulic ram from an Eagle Talon, and rear hatch chain with a hydraulic ram from a Nissan Pathfinder, approxamite cost $35.00 CDN.

· Installed 12/08/2004

43

Swaybar
- Swaybar linkage between sidecar wheel and motorcycle rear wheel to be fabricated, to minimize overall tendancy of rig to 'roll' in cornering and improve general high-speed stability.

1. Raw materials:
· 2 x 3/4" pillow block bearings ordered from Ted's Bearing supply on 18/09/2004. Cost $41.55 CDN.
· 4130 grade 5'x3/4" round stock and 4' x 1 3/4" x 3/8" bar stock purchased from ASAP Source on 18/10/2004. Cost $88.13 USD + shipping.
· Hiem joints, 2 x 1/2" left handed thread, 2 x 1/2" right handed thread, ordered from Ted's Bearing supply on 18/10/2004. Cost $94.67 CDN.
· Raw material for adjusting sleeve to connect Heim joints, from Metal Supermarket on 19/10/2004. Cost $32.46 CDN.

2. Fabrication:
· Swaybar linkage mounts for sidecar and motorcycle swingarms fabricated and installed 01/11/2004.
· Swaybar, motorcycle side pillow block bearing mount, fabricated and added to centerstand subframe mount on 11/11/2004. Cost $40.00 CDN materials and welding expense.
· Swaybar arms cut, drilled and bent to specifications on 18/11/2004. Cost $15.00 CDN labor.
· Swaybar, sidecar side pillow block bearing mount, fabricated and added to sidecar frame on 22/11/2004. Cost $30.00 CDN materials and welding expense.
· Swaybar jigged to sidecar rig, and arms welded into position on 22/11/2004, Cost $20.00 CDN materials and welding expense.
· Swaybar heat treated to 65C Rockwell and tempered to 45C Rockwell on 01/12/2004, cost $230.00 CDN including taxes..
· Swaybar assembly painted 08/01/2005.

· Project completed 08/01/2005.

44

Sidecar Brake Pedal Setup

- Despite having fabricated a 2nd brake pedal setup during last year's round of work, I've been unhappy with the results. I've decided to redo the setup, replacing all but the brake caliper and brake line with new components. A key part of my design is going to be a 'Siamesed' brake pedal setup, employing a custom fabricated footpeg, which replicates the brake lever pivot point of the motorcycle rear wheel, with a second brake lever on the end of the footpeg to activate the sidecar brake. Brake master cylinder, brake actuator, and brake pedal parts are to be obtained off of ebay for integration into this project.

1. Suzuki Bandit 1200 rear brake pedal, bracketry, brake actuator, and master cylinder.
· Purchased off of Ebay, cost $46.95 USD + shipping 04/11/2004.

2. Aluminum for footpeg bracket, and DOM tubing for component mounting to sidecar frame, $25.00 CDN appx from Metal Supermarket 23/11/2004.

3. Siamese'd footpeg bracket fabricated by 06/12/2004.

4. Brake lever bracket assembly fabricated by 14/12/2004.

5. Sidecar frame brake component mount assembly fabricated by 28/12/2004.

6. Custom fabricated 96" sidecar brake line ordered on 28/12/2004.
·Custom brake hose installed 15/01/2005, cost $204.54 CDN including taxes.

7. Project completed 16/01/2005

· Project completed 16/01/2005.

45

Markland Running Boards
A purchase of opportunity on Ebay, a set of Markland running boards as used on touring motorcycles was purchased for $48.00 USD + Shipping, 18/11/2004.

1. Will need to fabricate a mount on the left hand side of the motorcycle, similar to what i've constructed as a subframe for mounting the sidecar already, using the engine mounts.

·Purchased 1-1/2" tubing for left-hand mount from Metal Supermarkets, cost $16.50 on 25/01/2005.

· Left-hand mount fabricated and welded together 01/02/2005.

· Bracket clamp assemblies fabricated, appx total cost $70.00 CDN for welding, 03/02/2005.

· Assemblies painted and installed, 10/02/2005.

· Project completed 10/02/2005.

46

An on-again, off-again, on-again saga. Was going to fabricate a Leading Link front end using an automotive tire. Decided at one point home built might be more trouble to fabricate than it's worth, tried to buy an EZS front end, but no longer available. As of 25/01/2005, I am back to building my own front end, but will be using a 15" car tire ordered from Charnwood Classical Restorations.

Ah heck, this aspect of the project involved a 6+ page, itemized project listing in Microsoft Word. If you really are that bored and wish to view it, it may be downloaded and viewed at http://home.cogeco.ca/~wstrong/project.rtf

· Project completed 12/05/2005.

47

Auxilliary fuel tank
- Current range of the sidecar outfit is 150 km. I plan to fabricate an auxilliary saddle tank mountable to the sidecar frame with a capacity of approxamitely 3-5 gallons. Will require a fuel pump to be sourced and installed.

1. Raw materials:
·2002 Bandit fuel filler cap assembly and fuel petcock bought off of Ebay on 10/12/2004, Cost $52.26 USD + 15.50 USD S/H.

·Suzuki GSXR Fuel Pump bought off of Ebay 05/01/2004, $28.00 USD + Shipping.

·Project on temporary hold 08/01/2005 due to fuel cap assembly being damaged in fabrication of fuel filler neck. Need to obtain replacement cap and/or parts from wrecker or ebay before i can continue on with it.

·Project back on track as of 16/01/2005, obtained replacement fuel filler assembly from Zdeno Cycle Salvage, $50.00 CDN.

2. Fabrication:
·Fuel filler neck fabricated in aluminum, 08/01/2005.

· scheduled for ??

48

Auxilliary Battery setup
- I plan to install an auxilliary deep cycle battery into the sidecar, for extended operation of the stereo system, as well as improving cold starting characteristics of the motorcycle.

· scheduled for ??