Fasteddys side car build

Discussion in 'Antique Motorized Bicycles' started by fasteddy, Dec 20, 2009.

  1. fasteddy

    fasteddy Member****/index

    I've been building the side car for a couple of weeks now and just found out tonight how to hook photobucket up to the sight. Now none of you are safe.

    I saw a photo of a British Watsonian side car made for bicycles and started to copy it but the train went off the tracks along the line as you will see. It was supposed to be aluminum to start with.

    The first pictures are as it was this afternoon with the windshield attached. That will have plexiglass in it and the interior will be upholstered with Naugahyde.
    I wrapped the frame in 1/4" luan plywood so the mahogany strips would have something to rest against as I glued and nailed them.

    The mahogany came from window and door casings that my brother took out of the house 20 years ago when he rehabed it. The wood was just to nice to throw out.
    I cut it into 2" strips and then ripped them in half and ran them through the planer until they were an 1/8" thick. We have a small fully equiped wood working shop. We had to retire before we could afford it.

    The strips cupped when they were wet with glue and I had to sand the whole thing smooth. O joy. Lots of nail holes to fill as well.

    The batteries are going to go under the rear hatch. We can only have e-bikes in British Columbia.

    The colour will be dark with a red under tone but that is my personal choice.
    I spent over 40 years restoring antique furniture and really like the colour.

    If the wood hadn't been available I would have used mahogany veneered plywood or dark luan plywood or door skins. They can all look great.

    The finish will be 6-8 coats of gloss spar varnish sanded every 2 coats to keep it smooth.

    It will weigh about 50lbs when it is finished but I built it heavy on purpose. It has to counter balance me and I'm no feather weight.

    I'm going to build another one and I'll see just how light it can be made. I'll let you know when I start.

    Not sure how I'll attach it to the bike just yet but the bike has to be restored yet. It's the Monark in the pictures.

    Hope you enjoy the pictures and if you have any question or comments please feel free to e-mail or PM me.

    The one thing I will do different on the next build is to make it 1 1/2' x 4' not 2' x 4'. It is to hard to bend the plywood and strips around a. I just needed battery room but would not use that shape for an e-bike again.

    You will have to click on "my home" thanks to this site wiping out part of my photo bucket name.

    Last edited: Dec 20, 2009

  2. ModelA

    ModelA New Member

    I couldn't find the pictures

    I couldn't find the pictures, but i would like to see the side car
  3. DougC

    DougC Guest

    The rest of us have no way to know what "home" we're supposed to go to.

    Go to TinyURL, get a TinyURL link for your photobucket page, and then post the TinyURL link here.
  4. fasteddy

    fasteddy Member

    DougC, thanks and to everyone else sorry but Steve and computers are never used in the same sentence.

    The christmas rush is now over and I've had a chance to work out the tiny url thing as well as get finish on the side car.

    The site should take you from the finish to the start. See the note above to see what I did. I took the photos this afternoon.

    The questions that may come to mind, I'll try and pre answer.

    The exhaust pipes are down pipes from under a sink. New from Home Depot. I cut them to fit. Plugged them with plugs cut out with a hole saw and JB Welded in the pipe to keep things out. JB Welded the pipes into the side car.

    Hood scoops are drawer handles from Home Depot. The cover has to be pulled up to get to the battery. Only thing I could think of.

    The metal around the hatch cover is carpet strips that are used when you put carpet up to wood floors.
    I put very thin weather stripping under the metal to seal it against water. Yep, Home Depot.

    Seven coats of gloss spar varnish ,sanded very two coats with 220 wet/dry paper, used dry.

    Mohawk Refinishing Supplies, medium mahogany alcohol stain. Just because I like it and used it for years when I restored furniture. The colour choice is of course yours.

    I'll have the interior finished in a few days and will post photos of it. It will have a full canvas cover.

    Got a question. Please ask

  5. ibdennyak

    ibdennyak Guest

    You sir are a craftsman. You would have been handy to have around when I was trying to restore an old Chris Craft.
  6. fasteddy

    fasteddy Member

    ibdennyak,thank you.
    When my nephew gets back from Afgahnistan we are going to find him a Chris Craft and restore it.
    Wish I could have been there to help with yours.

  7. give me vtec

    give me vtec Active Member

    I cant tell how big it is... can you post up a pic with something next to it for scale??? Maybe that old vintage bike???

    Nice work though ed... its very pretty. It reminds me of one of those old wooden power boats from the 30's and 40's.
  8. fasteddy

    fasteddy Member

    Thanks vtec. It's 4 feet long and 2 feet wide or a 1/4 sheet of plywood. I'll put something in the photo in a few days when I have the interior done, so that you will get an idea of how big it is.

    I never thought of that. Thank you.

  9. SimpleSimon

    SimpleSimon Active Member

    Sweet. I've heard of boattail speedsters, that looks like you could pedal to the boat ramp, detach it, and get on the lake!

    Like that a lot. My son has been going nuts with boat building ideas the last few months, and one technique he has investigated is a very light weight bent wood torsion frame with a stretched fabric covering that is coated with resin that seals/shrinks it to the frame. I've been studying the notion of applying that technique to a sidecar build.
  10. fasteddy

    fasteddy Member

    Simon, my boat nuts brother wants to take it to the ocean and try it. He is sure it will float.

    Your right. That would make a killer side car build. Really light weight and strong.
    This one is around 50 lbs. Now the challenge is to build a light weight carriage for it.

    Like the boattailed speedster a lot. Have a new one in mind that is a copy of an old one.
    It will go in a whole new direction from the one I just did. Not a boat tailed speedster this time.

    This really is too much fun.
    Glad you like it.

  11. Turtle Tedd

    Turtle Tedd Member

    ...Outstanding..very nice
  12. fasteddy

    fasteddy Member

    I've got the interior in the side car and the frame is mocked up to give everyone a chance to see it and what I used to do it.
    Any one sees a problem or has a question please let me know.

    If we don't get a lot of rain this weekend I'm going to try and get it welded up.
    I've labled everything as to just what I'm going to do and the sidecar is designed to operate on it's own so the rider can lean left or right to make turns and not be stopped by a third bar/anchor point.

  13. fasteddy

    fasteddy Member

    Can't believe it's been two months since I got the frame cut out. Been bad weather and a lazy Steve combo. Steve also found out welding in a rain storm is not a smart move. Again!

    The welds are not pretty but it is the first time in about 50 years. I wasn't any good then either. Plan on a stronger welder and above all, lessons.

    Wouldn't think things like a simple brake caliper bracket would take two days to make but it did me. Works great though.
    Still working on how to put the sidecar on the bike but that is the next challenge.

    If the wind and rain stop soon, I'll paint it. Pounding rain and 40 mph winds at the moment. I have to paint outside and bring it in to dry.

    Any ideas or question are more than welcome.

  14. chefdouglas

    chefdouglas Member

    Great work! I have been thinking about making a side car, so PLEASE keep up dating you work. Your welds look fine from the photos and angles look square.
  15. Turtle Tedd

    Turtle Tedd Member

    Steve..looking good..Should be good and strong by using that heavy steel tubing.
  16. fasteddy

    fasteddy Member

    Thanks fellas. I'm worried about something breaking and once more the old guy finishes the trip with flashing lights and men in white coats.

    Got to start on the sidecar mount tomorrow and see if the bike lines up with the sidecar mount. Says it will in the book but it's lied to me before.

  17. fasteddy

    fasteddy Member

    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.

    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.

    Last edited: Apr 4, 2010
  18. Turtle Tedd

    Turtle Tedd Member

    sheetmetal cover looks nice.. like it was made by a old tin-nocker..Side car mounting pieces look good and strong..I will bet there will be no problem , even with Mona ridin in there
  19. fasteddy

    fasteddy Member

    Tedd, she's the love of my life but if she is going to ride on this rig, I'll need a gravel box on the side to get all of her in. Might need a thousand watt motor to get it going down the road too.
    Sure glad love is blind. I'm afraid to buy new glasses.

  20. Turtle Tedd

    Turtle Tedd Member

    Steve..dont buy new glasses..she has lost some weight but ....well what can I say