I realize this combo has probably been done countless times, but the whole thing is still new to me, and I want to draw on the expertise of "those who've been there before" to ensure that I'm doing it right. I've been busy over the Xmas holidays working on the sidecar. We've had unbelieveably mild weather for this time of year, which has allowed me to work outside quite a bit... except for yesterday where we had a minus 20C cold snap - Brrrr that was cold (still got a bit done out there tho). In order, I had DMC fabricate me the mounts and frame extension, installed the mounts, took the tub off the frame, had the extension tubing welded on to it, brought the frame in the house, cleaned up a bit of light rust, sanded/primed/repainted the frame, bolted 'er back together, and today I (finally!) hung the sidecar on the bike.
Still to do, in spring, I will install a Side Effects (Kamloops BC) Steerite triple tree (I have it already), and while the front end is apart, install Progressive springs, replace the seals/scrapers (I have a blown seal) and of course new fork oil.
I was shooting for about 55" of track and 9-10" of wheel lead, but wound up with 59" of track (outside of rear mc tire to outside of sidecar tire) and 12" of wheel lead - the frame extension could definitely have been a few inches longer! I haven't rigged the toe-in or lean out yet, but it's pretty close, and the way the mount adaptor hardware is configured, it should be relatively easy to fine tune it.
I do have one issue to deal with however... the upper mounts have a larger diameter hole than the 5/16" bolt that is in the diagonal strut clevises. I'll have to source or make bushings to close the gap. I'll post some pics here and am looking forward to your feedback with regards to the setup.
Everything looks like it is hooked up OK.
You'll probable need about 3/4" toe-in with the width of the rig. It's wider than I set them up but with the modified rake there won't be a steering problem and you will be a slight bit less apt to fly the car. I've always found the CSC struts used 3/8" bolts. If they are for 5/16" just drill them to 3/8".
Lonnie
Hi Lonnie - thnx for the feedback. The clevis ends look pretty small... not a lot of meat on 'em. Could take a close-up for you if you'd like. I'd prefer to bush the holes smaller on the mount stub (what do you call the male mount part anyway), or go to a larger clevis for the diagonal strut. Bushing the hole smaller seems cheapest way to go without compromising safety IMO.
Daryl
Hack'n - 12/28/2011 5:58 PM
I've always found the CSC struts used 3/8" bolts. If they are for 5/16" just drill them to 3/8".
Lonnie
Hey Lonnie, a little follow-up here. You were right, the strut bolts are in fact 3/8th" dia. Not sure what's up with the eyelet mount holes. They're smaller than a 1/2" and slightly bigger than 7/16th". I guess they're slightly oversize 7/16th" intended for 7/16" hardware?
I'm turning down some 3/8th" inside dia, 1/2" outsiude dia brass bushings to exact size to deal with this. It's all going to work out fine. Thnx again.
Daryl
Sounds like your eyeholes are Metric 12mm which is just under 1/2" SAE size.
L.
Our eye bolts which are on the mount set you have run a 12mm hole and are 12mm wide, The use the same 3/4 16tpi that California uses, Normaly we either thead in California eye bolts which have a 3/8 inch hole or we go with our 12mm eye bolts with female threads. What we have you do is cut the end off of your California sidecars struts and then tread on using red loctite our eye bolts. This will give you male eye bolts on both the strut and the mount. We then mount eye bolt to eye bolt rather then eye bolt to cleivis. The eye bolt to eye bolt mount is still stronger then the 3/4 inch threads on the struts. BTW, Champion sidecars also goes eye bolt to eye bolt with struts and eyes that look very similar to ours but are not of the same grade of alloy steel. Their struts and eyes are 1/2 inch wide with a 1/2 hole.
Usualy the Califonia struts stock end is not wide enough to fit over our 12mm wide eye bolts and there usualy is not enough material to drill them out to 12mm.
Jay G
DMC sidecars
www.dmcsidecars.com
866-638-1793
Thnx Jay & Lonnie for your input/feedback. That explains everything! No worries, just finished turning those bushings. Just have to size 'em to correct length and I'm good to go. This is best solution in my mind. No extra expense... just a little extra elbow grease :^)
Went to an industrial fastener supply house yesterday and got some new grade 8 3/8th" bolts for the struts, and got 'em installed today. The old bolts were almost fully threaded. I got bolts that had the proper length shank, figuring it'll wear less on the eyelet bushing and clevis ends. Got up to +2C this afternoon - got new grips installed/glued on. Simply unbelieveable weather for this time of year... sure makes working outside more pleasureable.
Warmed up well over freezing again today. Rolled the rig outside so I could take a few more pics. Yesterday it wasn't so warm (-13C), but I went out and changed the adjustment, raising the front end a bit more. CSC install instructions call for the front frame/mount to be set an inch lower than the rear. IMO that still leaves the tub with a very noticeable forward tilt to it, but it looks consistent with other installs I've seen. What would be considered minimum ground clearance? Looking on the Hannigan website I see they say they design for 6" clearance... I'm assuming this is minimum clearance at all points under the frame - I certainly don't have that at the front strut lower attachment point. That one point hangs a little lower than I'd like - might raise the front another inch or so yet. As I'm sure it'll draw comment, yes, I realize it needs more lean out.
Take a close look at this mount. It is an adapter that you fit into the frame, the put the strut into it. It gives me about 3 inches of up and down adjustment. It came from Jay at DMC. It would bring the front up for you.
I thought I had a better photo, but this is all I can find. Maybe someone else has one to post.
Thnx Mike. Never seen one of those before! Today, after work I went back out and had another go at it. I raised both the back, and the front (again), and I think I have it now. I have about 6 1/2" clearance or better at the critical low points that hang down. I also added 90 lbs of ballast to the tub, just in case I feel like giving it a whirl tomorrow - supposed to be +3C tomorrow!
Just a quick pic to wrap this up... success today. Got in a quick check-out ride to confirm all is well, and then came back, picked up the wife and went for a good spin around town. It made it up to +6.7C here today setting a record. Roads were quite greasy too, which made the experience even more interesting. No issues, but It'll take a while to get confident taking right handers at speed. The rig tracked well - no pulling, really neutral feeling in straight ahead riding, but steering is heavy. Looking forward to trying it with Steerite installed.
Congratulations on your maiden voyage Daryl.
Lee
MB5+TW200+CRF250L+GTV300+INT650
XL883R w/Texas Ranger Sidecar
Zuma 50F + Burgman w/Texas Sidecar<Mrs. SwampFox
Thnx Lee - it was fun! ...and satisfying too at the same time. I like the fact I did the install myself.
