I've got some more photos of the sidecar frame and mount. I plan to hold the sidecar to the frame but U bolts clamped on the seat stay and chain stay as well as the axle/bolt.
The tin is just a cover to make it look decent.
http://tinyurl.com/yajkqcz
Here is how I made the cover. made a pattern and traced it onto a piece of 3/4" mdf board. Turned a belt sander upside down and sanded it to the pencil line.
Routed the outside edge with a router and a 3/8" round over bit.
Put it on top a a piece of sheet metal and drew around it with a heavy felt tip marker. Cut it out up to the outside of the marker line with a sabre saw and a metal cutting blade. Wear ear protection. Belt sanded the metal edge smooth and to the marker edge.
After you square the metal on the form bend the metal in 4 places where the X's are. This helps to hold it in place. I bent it over about 1/2 way all around the edge then went back and finised it. Found if you start on the top and hammer over to the edge it goes better and tighter. Work different sections as you go.
The rest of the photos are how it will mount on the bike. There will be blocks cut from a hockey puck on either side of the stays so when the U bolts are tightened it will save the frame from being scratched or crushed.
The sidecar can be adjusted to be square with the frame and ride up and down so that there will be less chance of it lifting or diving in the turns since the bike will bank into the turns. I'll know more for sure if I'm not picking my self out of the weeds along the road side.
If you would like a pattern of the sidecar cover please PM me. Just be warned that it may not be for 2/3 weeks. I'll send it sooner if I can. The metal that clamps on the stays is 31/2" wide. I had to weld two pieces together.
Plan to paint the bike as soon as we get some good weather. Good friday the wind was doing 65mph and it was raining.
Questions or thoughts are always welcome.
Steve.