I'm back to trying to add weight to my sidecar. I have been carrying 50 pounds of lead and a 60 pound bag of concrete behind the seat in a very small location. The bag busted open and I'm done with concrete. Plus I need the space for a tool box and other items for upcoming road trip. And it dawned on me that this location is just the fiberglass tail section behind the frame. No real support. I'm worried carrying that much weight there could crack the fiberglass? I'd like for the frame to support at least some of the weight.
I now have another 50 pounds of lead. I would like to add an inner tubular frame inside the main frame of the sidecar, and fill it with lead. Now my welder guy don't want to mess with it. So I can have an exhaust shop bend me up the inner frame. I could then bolt it onto my main frame maybe. Would drilling 4 holes indicated by the blue lines in the attached pic weaken the frame, and I should not do it?
I'll try to describe this pic,,,lol. The yellow line is the new inner frame that I want the exhaust shop bend up. There's 4 small yellow dots that are the existing body mount holes. The blue lines are where I want to drill horizontal holes through and bolt the frames together. The black arrow is pointing at the cross angle part of the frame that is welded to the bottom of the main frame. I can rest my new frame on top of that to help carry the load at the rear. I guess I could actually bolt the new inner frame through the floor as well?
So what's you thought's? Sidecar Willie has examined it and say's he thinks welding would be better. But if we can't get a welder he thinks bolting it on will work.
My $0.02
Weld sleeves in the holes for the bolts to pass through and torque solidly against. With that the impact would be negligible. Otherwise tube clamps with threaded bosses could be used instead of holes.
The weight tube will eventually start bouncing, because the unsupported tube holes will crush in slightly over time. That will eventually elongate the holes & wear the bolts. Hence the reason for my suggestions to reinforce with sleeves welded through the tubes, or just use clamps around the tubes.
Hold my keyboard and watch this! 🙃
My $0.02
Weld sleeves in the holes for the bolts to pass through and torque solidly against. With that the impact would be negligible. Otherwise tube clamps with threaded bosses could be used instead of holes.
The weight tube will eventually start bouncing, because the unsupported tube holes will crush in slightly over time. That will eventually elongate the holes & wear the bolts. Hence the reason for my suggestions to reinforce with sleeves welded through the tubes, or just use clamps around the tubes.
Good idea about the welded in tubes. But at this point in time it's a no welding project. Unless I can get my welder to feel sorry for me.
As far as the clamps go. I don't think I could use a regular muffler clamp. There's only a 1/8'' rubber strip between the frame and body. So a regular clamp would be too thick. I wonder if I could use some kind of wide band clamp? The rear of the inner frame will be sitting on that cross bar to help support some weight. I think the front will want to sag down? But I could then also drill holes though the floor into the new inner frame?
I would plate under the area in front of the swing arm pivot.
Stitch welded.
Then fill with lead (shot?)
Then plate the top.
Weight is then out where it's needed.
Or do a Claud and plate the whole frame.
Here are two much easier ways to keep that Sidecar on the road, and avoid flying the chair.
# 1: Get a 150 lb dog to serve as big brother to Sidecar Willie.
# 2: Remove the Sidecar tire, fill it with sand, reinstall tire to wheel.
You're Welcome 
Two Million Mile Rider...All 7 Continents
Exploring the World in Comfort
My $0.02
Weld sleeves in the holes for the bolts to pass through and torque solidly against. With that the impact would be negligible. Otherwise tube clamps with threaded bosses could be used instead of holes.
The weight tube will eventually start bouncing, because the unsupported tube holes will crush in slightly over time. That will eventually elongate the holes & wear the bolts. Hence the reason for my suggestions to reinforce with sleeves welded through the tubes, or just use clamps around the tubes.
Good idea about the welded in tubes. But at this point in time it's a no welding project. Unless I can get my welder to feel sorry for me.
As far as the clamps go. I don't think I could use a regular muffler clamp. There's only a 1/8'' rubber strip between the frame and body. So a regular clamp would be too thick. I wonder if I could use some kind of wide band clamp? The rear of the inner frame will be sitting on that cross bar to help support some weight. I think the front will want to sag down? But I could then also drill holes though the floor into the new inner frame?
Flat fencing tube clamps, or just some 1"x 1/8" strap bent to clamp around the pipe.
@Brstr has a great idea to localize the weight to the outside of the car. 😎 Maybe a 200AH Li-Ion battery pack to run the DJ gear, with fold out lighted dance floor. 🍻
Hold my keyboard and watch this! 🙃
Here are two much easier ways to keep that Sidecar on the road, and avoid flying the chair.
# 1: Get a 150 lb dog to serve as big brother to Sidecar Willie.
# 2: Remove the Sidecar tire, fill it with sand, reinstall tire to wheel.
You're Welcome
Aint it kinda early in the day to start drinkin,,,,lol.
