Eddie’s BMW R80 / Velorex 562 build

Forums Forums Sidecars Sidecar Builds Eddie’s BMW R80 / Velorex 562 build

This topic contains 76 replies, has 7 voices, and was last updated by  Box.a.Bits 1 week, 1 day ago.

Viewing 15 posts - 16 through 30 (of 77 total)
  • Author
    Posts
  • #5859

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    Over to the brother in laws again today for some more work on the bike

    Looking very naked

    New higher and wider handlebars half fitted. It took much longer than expected as I had to re route a lot of cabling

    #5860

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    Still to do: (this list may change as time progresses)

    Get a new starter motor – (Arrived 25/05)
    Get new Horn – (Arrived 25/05)
    Get the right keys
    Possibly get a new battery (done)
    Get a new exhaust pipe (Not required now)
    Wire brush & paint exhaust headers (Dependant on getting exhaust spanner)
    Get exhaust spanner (Organised)
    Build a subframe for the sidecar (in progress)
    Attach sidecar to subframe
    Build a wiring loom for sidecar lights
    Get sidecar dialled in
    Ride it!

    #5861

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    More work on the bike today, I finished mounting the new handlebars and we lined up the bike and chair. My brother in law Roger has made most of the subframe, though it’s not fitted in the pics below. It’s really only the upper rear mount that needs sorting out now.

    #5862

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    More pics, the front subframe being mocked up

    and taking a leaf out of Coriman’s book, 10mm plate for the side

    #5863

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    More pics

    Front part of subframe fitted

    Front upper mount closeup

    Front lower mount

    Looking down towards front mounts

    #5864

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    and more

    Center support

    Sub frame attached to center support

    Frame for upper rear mount

    #5871

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    So it turns out I have a custom top fork clamp, which means my headlight ears won’t fit as the custom clamp is significantly thicker than the stock one.
    Coriman may be able to make a replacement, if my measurements are the same as his earlier twin shock top yoke.

    Steering Stem – 27.51mm measured at the thread of the steering stem, Steering stem hole 33mm as the stem nut has a ridge that fits into the hole in the yoke that locates everything.

    Fork staunchion thread -25.49mm measured at the thread at the top of the staunchion. My largest adjustable wrench wasn’t quite big enough to get the nut undone.

    #5877

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    For Coriman

    The original top clamp was this

    http://www.motobins.co.uk/bmw-parts.php?model=R%20Series%202%20valve%20Twin&bikeref=R90-6
    TOP YOKE 1985 ON TWINS (NOT PARALEVERS)
    BMW Part No. 31 42 1 452 135
    29107.jpg

    The steering stem hole is 33mm, the staunchions are listed as 38mm and we measured the staunchions on my bike with a set of digital verniers as 38.5mm, with the hole being 38mm

    The nut at the top of the fork is this. The total height of the nut is 12mm with 8mm of that being the hex section and 4mm being the inset section.
    STANCHION NUT 40mm (FITS ON TOP OF SPRING RETAINER UNDER CAP 29003) 10/85 ON 2V TWINS.
    BMW Part No. 31 42 1 454 959

    29224.jpg

    #5879

    Coriman
    Participant
    • Location:
    • Bike:
    • Rank: 125cc Rider

    There are still a few things to sort out with your fork yokes.
    The stock plate top yoke is held by 3 points.
    The steering stem nut spigot at 33mm with matching hole in yoke.
    The fork stantiions should be larger than the corresponding holes in the top yoke, since the fork nuts draw the stauntion up to the the yoke but not through it.
    They are located by the fork nut spigots, under the hex. What diameter are they? because that is what dictated the size of the hole in the yoke not the stauntion size. Unlike your aftermarket yoke.
    Also the distance between centres is critical?
    That’s fork stauntion centres and also centreline of fork tops offset to centreline of steering stem.
    Also there are several holes for handlebar risers and instrument brackets etc. They all need to be identified and located by measurement from a datum . Diameter of hole need to be specified etc. in a working drawing.
    The distance from fork top to centre of bottom yoke as well as wheel spindle to lower yoke centre. The reason for all this is that I cannot assume that your forks and yokes are the same as mine, as indeed they are not. I can see from your pictures that the bottom yoke is much heavier than mine, so it is possible tha they may have to be relieved at 3 degrees to accomodate the new fork angle. Its not quite as simple as a bolt on part, and not to be rushed into.
    With your set up what wheel track rear wheel centre to sidecar wheel centre are you using? Also what sidecar wheel lead have you chosen?
    These two things effect the steering effort required.

    #5880

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    Think I’ll just have to get a stock clamp at the moment and try and ride it as is. I don’t have easy access to the bike to strip it all down and measure up in the next week or so to have a yoke made up before Cold Kiwi.

    #5881

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider
    #5882

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    More work on the bike last night, the front end came out and gaiters, headlight ears and headlight shell, and a stock top plate were all installed. It’s starting to look like a bike now

    #5883

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider
    #5884

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider
    #5885

    Eddieb
    Keymaster
    • Location: Hamilton
    • Bike: Suzuki DR650 ADV
    • Rank: 1200cc Rider

    last one

Viewing 15 posts - 16 through 30 (of 77 total)

You must be logged in to reply to this topic.