When a crazy idea becomes reality

Nov 2, 2016
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Did a little more today.
This is the rear of the underside



Made in the same way as before.

This is just the rough shaping, I have loads more to do to smooth it all out. The two halves don't quite flow together, so I'll work on this before I weld them together.



I feel like I've made an aluminium canoe! Good job it's not snowing here or I might have been tempted to use it as a sledge lol
 
Nov 2, 2016
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It's a little something I made a few years ago. I've kinda pinched a few parts off it over the years lol

It used to look like this



:)

It's actually thanks to this that I got the job. I was riding it round when I saw the workshop full of vintage cars. I went in and asked if he was hiring. He said that if I could show I could fabricate he would think about it. I showed him the bike I'd propped up outside. He took me on there and then!
 
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It amazes me the level of talent and creativity of people that find their way to this site.
 
Nov 2, 2016
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It amazes me the level of talent and creativity of people that find their way to this site.
The world is full of talented people !

Although I'm from England I like this site and chose it to do my build blog. The english based cycling sites tend to be aimed more at the lycra wearing road warriors and less at the more open minded. If it wasn't for my kids I'd be living in usa. I have worked over there and had plenty of job offers.......
 

LukeTheJoker

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It's a little something I made a few years ago. I've kinda pinched a few parts off it over the years lol

It used to look like this



:)

It's actually thanks to this that I got the job. I was riding it round when I saw the workshop full of vintage cars. I went in and asked if he was hiring. He said that if I could show I could fabricate he would think about it. I showed him the bike I'd propped up outside. He took me on there and then!
:happy: Great story! I wouldn't want to sell it either!
 
Nov 2, 2016
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Done some more today :)

Once I was happy with the fit on the buck of the two halves, it was time to weld them together. With aluminium tig welding cleanliness is everything, so the edges that are to be welded are chemically cleaned then gone over with a rotary wire brush



Then, after a final fit check, they are tacked together



Then fully welded

 
Nov 2, 2016
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The welds are then crushed between a hammer and dolly



At this point it was obvious that there was a flat spot on the main part. Rather drastic measures were called for as it's now too big for me to get into the english wheel. Out came the big hammer lol



Again more smoothing out with a flat hammer and dolly, then the body file is run over the area



This highlights the high and low spots. The low spots are stretched upwards, again with hammer and dolly. This is known as planishing and it's boring!

After a while the panel starts to come good



I plan to have this sidecar in polished bare metal so much more planishing lies ahead.....:(
 
Nov 2, 2016
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Planishing planishing planishing......

I am working on this but not bothering to post photos........"oh look, that bit is now slightly smoother" lol
I spend half an hour or so on it most mornings as a "warm up" for work :)

Nearly finished the underside now. The next job is to start making the sides. These will be smaller panels and (hopefully) quicker.

I plan to spend half a day on it on Friday so I should be posting pictures then.