VW Bus Sidecar build

Discussion in 'BUILDS' started by Bullyboy, Jan 26, 2019.

  1. Bullyboy

    Bullyboy

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    after riding my old Mongoose with the sidecar for a couple years I decided to build a new sidecar to go with a new Kona.
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    I started with some 6061 for the frame this time to shave some weight off the old steel frame design.
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    Last edited: Jan 26, 2019
  2. Bullyboy

    Bullyboy

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    the sidecar is a bit of a process for baking the blank for the sidecar shape. I start with styrofoam and some wood shapes for the rough shape.
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    first layer
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    second layer
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    some shaping
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    starting to look like something
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    now it looks like something
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  3. Bullyboy

    Bullyboy

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    adding the rib to the body.
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    adding the telltale nose detail
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    the form painted with latex, beside the original sidecar, a little size comparison
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    I wanted it to be big enough she could lay down when she was tired
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  4. Bullyboy

    Bullyboy

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    now for some sloppy work with epoxy, 'glass , and carbon fibre. The last sidecar had several layers to get the stiffness I wanted, this time 2 layers of biaxial carbon fibre added quite a bit of stiffness without the weight
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    1 layer of fibreglass, 2 layers of carbon, 1 layer of fibreglass and dacron on the top to smooth the whole thing out. The dacron strips off after and leaves a finish that is ready to add more layers.
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    then you get to melt the foam out of the inside.
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    just had to set it on the frame to see how it looked.

    [​IMG]
     
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  5. Bullyboy

    Bullyboy

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    the boss approved of this new design
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    cut in some tail lights

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    started bodywork, and cut in some headlights
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    fill , sand, fill, sand and on and on.
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    my shaping block so I could get all the ribs the same shape.

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    had to throw some high build primer on to see how things were going, after a while all the patches start to confuse things

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    and more guide coat to see where we need some attention, back to sanding again
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  6. bficklin

    bficklin

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    Beautiful work sir, you are indeed very talented.


    Sent from my iPhone using Tapatalk
     
  7. LukeTheJoker

    LukeTheJoker Moderator

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    Really nice work!
    Did you vacuum bag the carbon layers?

    I have done some fiberglass work helping build a catamaran, but never played with carbon fiber.
     
  8. Robertk

    Robertk

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    Yes great work!
     
  9. Bullyboy

    Bullyboy

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    .
    I use Dacron sheet on the top of the layup, you can squeeze out a lot of excess epoxy and get a nice compact layup
     
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  10. Bullyboy

    Bullyboy

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    I was tired of sanding and filling, so I spent a couple hours poking holes in my frame, for a grand total of 2 ounces difference. :43:
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  11. RustyGold

    RustyGold

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    Outstanding :thumbsup:
     
  12. Bullyboy

    Bullyboy

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    More sanding and patching, at least the repair spots are getting smaller.

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    Added trim around the windows as well
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  13. Bullyboy

    Bullyboy

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    220 &400 grit , it’s getting closer , we’ll see after the primer dries
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  14. KJV

    KJV

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    :41::thumbsup::thumbsup:
     
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  15. LukeTheJoker

    LukeTheJoker Moderator

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    So very cool!
     
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  16. NoControl

    NoControl

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  17. Pushie Pirate

    Pushie Pirate

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    Man that is so cool, super well done!
     
  18. 93EXCivic

    93EXCivic

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    Awesome sidecar.
     

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