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Old 02-26-2010, 10:26 PM   #1
Clancy OP
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Location: Land of droughts, and flooding rains
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Another Aussie outfit build

Yes, Another one

Unlike 3legs "Ultimate Hack" this one will be a start from scratch build, with a new to me K1100, and no previous sidecar building experience, apart from giving NevGriff a bit of help with his.

This whole saga has it's origins in a return to riding solos after many years away from bikes, riding to rallies, meeting a lot of outfit riders, and finally, a trip to Top Hut station, and the realisation that I had an aversion to riding a loaded heavy Honda twin in sand

Australia has a very rich sidecar history, with some very unique and original outfits; I'd heard of some of the exploits of outfits like the legendary Tuck Truck, and on one particular ride, admired the ability of these blokes to carry all the luxuries, including in one instance, all the equipment and iingredients to have steamed barramundi for dinner.


The Tuck Truck



Aussie outfits, including Phyllis's Burgman rig.


More







Mungo's camo outfit















The REAL Phyllis in the Burgman




Doing it in Style. McCardigan, preparing the steamed fish.


As can be seen from the pics, there's a huge diversity in the design and looks of Aussie outfits but they all have the ability to cover the big miles, with some big loads, over some very questionable roads, and camp. in reasonable comfort at the end of it.
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Clancy screwed with this post 02-26-2010 at 10:37 PM
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Old 02-26-2010, 10:55 PM   #2
Clancy OP
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Having admired the way these blokes travel to rallies, and spoken to a few about building an outfit, I finally made the decision. During all the questioning, one of the recommended bikes was a K1100 and luckily, one became available, at the right price, and in reasonable condition.


This was my first look at it. 87,000 kms, which I'm told, makes it only a youngster
Once I got it home, I started having a closer look, pulled a few things off it. The bloke I bought it off was the second owner and, though it looked ok, was showing signs of living out in the open.
The original intention was to do what was needed to mount a sidecar and go riding. Once I started having a closer look, I soon realised that the bike needed a bit of work before I'd be doing any long distance trips.

Doesn't look too bad







SioI started pulling parts off, Sold the panniers, the radio, and a few other bits and pieces. Lower fairing removed and sold as it wasn't going back on.






As I went along, I started finding little things that would need fixing.



One of the lugs had broken off the upper fairing so I glassed it back on.


Found some very dodgy switch repairs.





The seat was delaminating and cracking along the corners.


I didn't like the front guard but that was going to come off anyway as I'll be fitting leading links. I found out that the forks had been reconditioned the week before I picked the bike up, as a roadworthy certificate item.
They'll be sold anyway.


I realised at this stage that the bike needed a fair bit of work. I noticed a slight leak at the rear main seal, and most of the fuel plumbing needed attention. I'd also noticed a faint gearbox noise, so off to Ringwood BMW.
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Old 02-26-2010, 11:17 PM   #3
Clancy OP
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The bike came back with new rear main seal, clutch kit, and new gearbox bearings. Only one of the bearings was a bit suspect but while the gearbox was out, it seemed silly not to do the job properly.




Once the bike came back I continued finding things that needed attention. The switch panel was cracked and would need replacing. The electric screen was sold and would be replaced with something lighter.




I made an attempt at making a new panel but it didn't come out the way I wanted so was pushed onto the back burner for later.

So far, the job had taken longer than I thought, and this was going to be the way things would go for most of the build.
I gave up on the bike at this stage and decided to make a start on the sidecar. I had a few ideas in mind, though nothing firm. I wanted to carry a fridge, I didn't want to carry jerry cans, so decided to fit a purpose built fuel tank.
There were a few ideas of mounting points, lots of storage space, and a second battery. With that in mind, no previous sidecar building experience, and little else, I made a start with some square tube.





As I worked, I formed a bit of a picture, with the fridge on the back, fuel tank and battery somewhere in the middle. From what I'd read in here, from Claude and others, the intention was to keep the main weight inside the triangle formed by the three wheels.



Note the square front. This was to change as I went along.

At this stage, I got involved with NevGriff and the build of his Ural sidecar/1150, and, through that, got to talk to Phyllis, who was a mine of information and ideas. More of that later.


Phyllis's work on this was nothing short of brilliant.





Where I planned to put the fridge.








The fuel tank. 35 litre, sponge filled.

More later.
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Old 02-26-2010, 11:39 PM   #4
3legs
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Heap of shit.

Nah just kidding. For a sidecar virgin I reckon you have done a brilliant job. Most impressed.
Now if you can just get it finished for the OCR.

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Old 02-26-2010, 11:44 PM   #5
Clancy OP
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Originally Posted by 3legs
Heap of shit.

Nah just kidding. For a sidecar virgin I reckon you have done a brilliant job. Most impressed.
Now if you can just get it finished for the OCR.

3legs
Ok Smart ass. What did you do to yours today
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Old 02-26-2010, 11:51 PM   #6
3legs
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Who me. Never. Check out my site.

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Old 04-05-2014, 12:00 AM   #7
KLR 650 guy
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Another Aussie outfit build

Hi there Clancy ..

Now I am amazed with all you have done on here M8 ..

Just read all this post today (taken 5 five hours )..

Love the new rig but you have better show me how I can do one of these for my KLR650 coz I whent the cheap way out with buyin a Ural sidecar Outfit myself so my Dog (Missie) can have some comfort now she is 8 and gettin older each day (like us) ..

Missie use to ride on the back of the KLR650 ( still dose when I'm on it )everywhere I whent with a couple big trips done of 1,600km as all this riding I do on and off farm.. So now she has comfort with the Ural ..

Thanks for a great build / ride report on Mk1 and lovin this Mk2 that I only see parts of .. Chair chassis looks great BTW ....

CANT WAIT FOR YOU TO FINISH IT ....





Robert
Esperance Wa ....


Sent to where ever I like .. Lol ....
Mostly on IPad with tap talk ....
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08 Klr650e is the starting point ..ooo kms ..Kaoko cruz control..Rekluse Clutch..Staintune pipe..
Tall Kawa screen..Cog swapin 14, 15, 16, 42, 43.. Now he has bought a URAL Tourist where to now folks ....
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Old 04-05-2014, 12:55 AM   #8
Clancy OP
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Quote:
Originally Posted by KLR 650 guy View Post
Hi there Clancy ..

Now I am amazed with all you have done on here M8 ..

Just read all this post today (taken 5 five hours )..

Love the new rig but you have better show me how I can do one of these for my KLR650 coz I whent the cheap way out with buyin a Ural sidecar Outfit myself so my Dog (Missie) can have some comfort now she is 8 and gettin older each day (like us) ..

Missie use to ride on the back of the KLR650 ( still dose when I'm on it )everywhere I whent with a couple big trips done of 1,600km as all this riding I do on and off farm.. So now she has comfort with the Ural ..

Thanks for a great build / ride report on Mk1 and lovin this Mk2 that I only see parts of .. Chair chassis looks great BTW ....

CANT WAIT FOR YOU TO FINISH IT ....





Robert
Esperance Wa ....


Sent to where ever I like .. Lol ....
Mostly on IPad with tap talk ....
Thanks Robert. Must say I'm looking forward to finishing it too mate. I bought a dog a while back and hoped to take her on trips. Heeler/Kelpie cross from the rescue people. But she hates the bike and won't even get in the car and she's grown a lot bigger than I thought she would. So she'll be staying home.
I'd willingly show ya how to build one, but don't ask me to help I swore I wouldn't build another after the last couple and this time I mean it
I'll post up the complete build of this one from scratch eventually and maybe you can use some of the info for yours eh.
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Old 04-05-2014, 01:09 AM   #9
KLR 650 guy
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Hi Clancy ..

Kool beans ..

I was lookin at buyin one of them off-road rigs from that bloke in Sa ( Crow country ) (ex Vic here Heee Heee ) but just didn't get the money to buy it .. So just might think bout building one instead as like not gettin any better .. Lol ....

;-) ;-)



Sent from my iPhone using Tapatalk
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08 Klr650e is the starting point ..ooo kms ..Kaoko cruz control..Rekluse Clutch..Staintune pipe..
Tall Kawa screen..Cog swapin 14, 15, 16, 42, 43.. Now he has bought a URAL Tourist where to now folks ....
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Old 04-06-2014, 03:07 AM   #10
Crustyvarmint
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That's looking very nice Neil.
It looks to be up to your usual high standard of workmanship.
Looking forward to seeing the finished product mate.
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Old 04-06-2014, 05:50 AM   #11
Clancy OP
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Originally Posted by Crustyvarmint View Post
That's looking very nice Neil.
It looks to be up to your usual high standard of workmanship.
Looking forward to seeing the finished product mate.

Thanks Derek. I'm looking forward to getting it finished too mate Getting a bit tired of 4 wheels.
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Old 04-07-2014, 02:43 AM   #12
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Nice work Clancy.
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Old 04-07-2014, 03:27 AM   #13
Clancy OP
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Nice work Clancy.

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Old 04-14-2014, 11:19 PM   #14
Crustyvarmint
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Did you smuggle out any pics Nev?
I've tried using a satellite camera, but the garage door gets in the way.
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Old 04-15-2014, 01:09 AM   #15
nevgriff64
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Did you smuggle out any pics Nev?
I've tried using a satellite camera, but the garage door gets in the way.
Sorry mate, he didn't take his beady little eyes off me for a more than a second.
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