Hello and welcome to the final installment of my BMW Duo-Drive Sidecar Conversion.
You can read Pt I of the build here,
Pt II of the build here,
Pt III of the build here,
and Pt IV of the build here.
Looking through all the pictures I shot and revisiting all the modifications that we did to my sidecar build, I could probably write another 2 installments of this build. We made many modifications to this outfit, for quite a number of reasons. One of them was simply because we could. Ad Donkers of LBS Sidecars is the type of guy that likes a challenge, so for example when I threw out the locking hub idea for the sidecar wheel to him, he wanted to do it not only as a personal challenge but also because it was a very practical idea. The same can be said of many of the optons that we built on this outfit. We worked very well together, and the outfit turned out better than I imagined truth be told.
If I never smell epoxy and fiberglass resin again, it'll be too soon. I had a white dry nose for a week after all the cutting and sanding was finished.
The carrier plate of the Wunderlich TRW Sintered Clutch is hardened stainless steel, and the 2 friction plates are made of a high quality material riveted to the carrier plate with heat resistant rivets.
The other mechanical modification I made was to the Final Drive, a weak link in the 1150 and 1200 boxer engine for some, but in my case I have been lucky and never had any issues.
Since I changed the final drive unit completely by going from a 31/11 ratio to a 37/11 ratio it gave me a chance to replace the final drive bearing and specifically make a modification to the little oil channel in the housing, which I will share in detail with you now.
This was also a good time to go through all the wiring and check all the connections. Some were good, and some were badly corroded. I soldered most of the new connections and gave all connectors a good coating of electric grease.
The next day the metalwork came in from the powdercoaters,
which meant 'Final Assembly'.
This was a moment I was ignoring all along so as not to get caught up in the moment and rush through anything, but now here it was at long last.
And then the leading link.....
...and the front shocks.
The cradle where the Duo-Drive will sit.
The Mobec Duo-Drive installed with the outer axle. The outer axle is an unaltered half shaft from a Suzuki Vitara 4X4. We made a 2cm spacer to make it fit perfectly without having to cut it.
The exo-cage for the front nose of the sidecar. Behind the cage on the table are the rest of the powder coated parts awaiting assembly.
I used the original BMW turn signal from the right side of the motorcycle rather than an aftermarket one, it looks good and keeps it simple. Ad was not in agreement with this, he didn't think it looked good.
I do, and thats all that matters, right?.
The Bosch car battery in the bottom of the picture is being measured up for an external battery tray. It's a little smaller than a full-size car battery, but has the same power.
Having the ability to be able to carry an extra battery gives me much more cold starting power since the next 6 months of my travels will take me through to Sweden, Norway, Finland and Russia starting in October of this year and going through February of 2013 where average temperatures will be about -25° and go as low as -50°. The small Odyssey motorcycle battery, strong as it may be, just doesn't keep up with severe winter temperatures, as I found out in -25° in Colorado in January of last year.
At this point we were ready to put on the boat otherwise know as the sidecar.
All shiny and freshly painted, way to clean for me, but by the time I reach Oslo in October, it should have a nice patina to it.
I'm sure that knowledge will come in handy in the field, literally.
I ought to do a complete and comprehensive list of all the improvements and upgrades that we did to this rig, as well as the upcoming
"Russia in -40°" checklist.
My next post will will probably be from Denmark, I hope.
I intend to leave Holland by next Tuesday, Sept 25th with a stop in Monheim Germany to see my Friends Jurgen and Bub, and then up through Germany to Denmark. I had wanted to stop off in Berlin for a few days but have decided to leave this part of the trip for the way back in January in order to allow myself a good time buffer for Russia. Even though I don't run on a schedule, I have ben invited to a Motorcycle rally in Yaroslavl, Russia by the Black Bears MC whom I met at the 2012 EGT in Luxembourg. The rally is the first week of December so it's not a lot of time for me to travel 6,700kms in Winter in sub-zero temps, that's providing I make it all the way over to Moscow to begin with.
Have the day of your choice,