DR650/hack custom build pics

brockoli · 03-11-2010, 11:58 PM

brockoli · 03-12-2010, 12:00 AM

Lots of details on this. I can post them if you're interested in knowing more.
-Brock

Qwik · 03-12-2010, 01:07 AM

Looks good so far. Post up the Details

DerViking · 03-12-2010, 05:23 AM

+1

Interesting looking build. I assume that the early couple of pictures are subframe for the bike. Im curious to see how you hook to the bike.
Interesting suspension design. Looking forward to seeing it all put together!

Mac · 03-12-2010, 07:48 AM

Quote:

Originally Posted by Qwik

Looks good so far. Post up the Details

And pics at least 800 x 600 so we can see them... (please)...

Bollocks · 03-12-2010, 07:57 AM

Quote:

Originally Posted by Mac

And pics at least 800 x 600 so we can see them... (please)...

Click on the pic.
Thats a nice looking rig Brock

brockoli · 03-12-2010, 09:16 PM

here is the details on this build:
-subframe bolts between the foot peg mount on main frame on both sides and tags the sidestand mount as well
-at the front of the subframe, it goes up in front of the single downtube on the frame and there is a flat plate with 2 weld nuts on it that slides up inside the stock frame tube. the subframe has a tab at the top of the tube and a tube welded through the tube lower down and all bolts to the bike.
-both the upper and lower front mounts come off this tube, no clamps.
-the rear subframe incorporates a rack and grab handle on the outside as well as the new muffler hanger mount.
- the rear subframe ties in and triangulates with the front lower subframe and helps brace everything together.
- i also incorporated a smaller diagonal tube under the seat that helps eliminate any twisting of the stock frame work at the seat/fender area which is very small and flexy in stock form
- the upper rear mount attaches plate to plate on formed tabs and the lower mount is almost half way down the swingarm to allow for a decent spread between lower mounts.
-I built the sidecar frame from scratch and it is built to accomodate his 2 dogs.it has a small cut down windscreen.
-the rear framework of the car is not completed but will incorporate a sealed ammo box for his camera and gear and doubles as a step for the dogs to jump in from the rear.
- Car is getting sheeted in aluminum panels bolted to triangular tabs that are welded to the framework
-the suspension is a fresh take on design for a sidecar, I built it to allow for smooth wheel travel (the longer the arms, the smoother the ride)
-I used 1 ton truck tie rod ends in the end of the swing arms/radius arms and this allows them be sealed, lubricated and reliable (rod ends work too but need replacing and dont like expossure to dirt)
- the shock will mount on the fabricated gusset on the rear arm and be angled towards the bike to relieve the stress on the sidecar frame and stay out of harms way. Basically it lets the frame just hold itself up and deal with swing arm stresses (the rear arm is pushing against the bike in left turns and transmits the force to the bike frame, stronger than the cars is
-the hub was tricky... as we all know single sided axles need to be a decent size or they fail. so, fresh thinking again. I machined out the hub a little to clear a 5 bolt trailer stub axle (1.25" stub shaft!). turn the hub around so it's backwards to how it would normally be on a trailer. put the axle stub through the bike's wheel hub that has machined steel spacers instead of bearings in it and tighten up the 3/4" bolt in the end of the stub that was machined and threaded. this holds the wheel to the axle. The other side has a machined ring TIG welded on to act as a stop.
-The 5 bolts on the hub facing the inside of the rig accept the 2 radius arms that get bolted to it. Simple, strong, easily greased and adjusted and will retain the stock rotor on the stock rear DR650 wheel to allow for a brake. thats it, in a reasonably large nutshell.

-the front end of the bike has 2 HID lights that I made an aluminum mount plate on each side to incorporate the fairing and fabricated dash/switch panel.
-front of side car in the middle of the nose has 2 lights that match the bikes HID's
-oh ya, custom built stainless exhaust out, down and back up to a GSXR muffler with turned down tip so it doesn't drink the rain and dirt
-Brock Smith

03-11-2010, 11:58 PM	#1
brockoli ^OP Gnarly Adventurer Joined: May 2009 Location: Kamloops Oddometer: 179	DR650/hack custom build pics

03-12-2010, 01:07 AM	#3
Qwik Two Wheeled Addict Joined: Apr 2008 Location: Sunnyvale, California Oddometer: 5,247	Looks good so far. Post up the Details __________________ Speed bumps never seem to make me go any faster

03-12-2010, 05:23 AM	#4
DerViking Shred Joined: Mar 2006 Location: Black Bill Park Oddometer: 179	+1 Interesting looking build. I assume that the early couple of pictures are subframe for the bike. Im curious to see how you hook to the bike. Interesting suspension design. Looking forward to seeing it all put together! __________________ ATGATT: When you fall off your motorcycle, you will be wearing what you were when you got on your motorcycle. Dress accordingly.

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03-12-2010, 12:00 AM	#2
brockoli ^OP Gnarly Adventurer Joined: May 2009 Location: Kamloops Oddometer: 179	Lots of details on this. I can post them if you're interested in knowing more. -Brock

03-12-2010, 09:16 PM	#7
brockoli ^OP Gnarly Adventurer Joined: May 2009 Location: Kamloops Oddometer: 179	here is the details on this build: -subframe bolts between the foot peg mount on main frame on both sides and tags the sidestand mount as well -at the front of the subframe, it goes up in front of the single downtube on the frame and there is a flat plate with 2 weld nuts on it that slides up inside the stock frame tube. the subframe has a tab at the top of the tube and a tube welded through the tube lower down and all bolts to the bike. -both the upper and lower front mounts come off this tube, no clamps. -the rear subframe incorporates a rack and grab handle on the outside as well as the new muffler hanger mount. - the rear subframe ties in and triangulates with the front lower subframe and helps brace everything together. - i also incorporated a smaller diagonal tube under the seat that helps eliminate any twisting of the stock frame work at the seat/fender area which is very small and flexy in stock form - the upper rear mount attaches plate to plate on formed tabs and the lower mount is almost half way down the swingarm to allow for a decent spread between lower mounts. -I built the sidecar frame from scratch and it is built to accomodate his 2 dogs.it has a small cut down windscreen. -the rear framework of the car is not completed but will incorporate a sealed ammo box for his camera and gear and doubles as a step for the dogs to jump in from the rear. - Car is getting sheeted in aluminum panels bolted to triangular tabs that are welded to the framework -the suspension is a fresh take on design for a sidecar, I built it to allow for smooth wheel travel (the longer the arms, the smoother the ride) -I used 1 ton truck tie rod ends in the end of the swing arms/radius arms and this allows them be sealed, lubricated and reliable (rod ends work too but need replacing and dont like expossure to dirt) - the shock will mount on the fabricated gusset on the rear arm and be angled towards the bike to relieve the stress on the sidecar frame and stay out of harms way. Basically it lets the frame just hold itself up and deal with swing arm stresses (the rear arm is pushing against the bike in left turns and transmits the force to the bike frame, stronger than the cars is -the hub was tricky... as we all know single sided axles need to be a decent size or they fail. so, fresh thinking again. I machined out the hub a little to clear a 5 bolt trailer stub axle (1.25" stub shaft!). turn the hub around so it's backwards to how it would normally be on a trailer. put the axle stub through the bike's wheel hub that has machined steel spacers instead of bearings in it and tighten up the 3/4" bolt in the end of the stub that was machined and threaded. this holds the wheel to the axle. The other side has a machined ring TIG welded on to act as a stop. -The 5 bolts on the hub facing the inside of the rig accept the 2 radius arms that get bolted to it. Simple, strong, easily greased and adjusted and will retain the stock rotor on the stock rear DR650 wheel to allow for a brake. thats it, in a reasonably large nutshell. -the front end of the bike has 2 HID lights that I made an aluminum mount plate on each side to incorporate the fairing and fabricated dash/switch panel. -front of side car in the middle of the nose has 2 lights that match the bikes HID's -oh ya, custom built stainless exhaust out, down and back up to a GSXR muffler with turned down tip so it doesn't drink the rain and dirt -Brock Smith