Inside Frame Rail layup finished

Frame Rail layup done on the inside of the body.  Now I will flip the body over and finish the underside layups.  Then I will finish the layup to isolate the engine.  Making progress. 

Frame Rail Layup

 Doing a bit of a layup.  Still have a lot left to do.  Once the frame rail layups are done on the top I will finish the underside and then on to mounting the shocks.

Need to do the layup where the blue foam is showing.  I have to move it down so I can reach it much easier.  I have done the sanding so that the new layup will bond to the existing fiberglass.

Rear Suspension Shock Mount

 The steel fabricated shock mount.  I wanted to get something done in December.

A cardboard fabrication of what was wanted for a shock mount.  I also worked on the head light mold.  And am prepping the body for the lay up where the frame rail will sit.  I also finished some welding on the frame supports.  I also got the shock mount kit for Christmas and have some additonal work before those can be mounted.

Finishing the cut out for the fram rails

 After cutting the floor on the drivers side for the frame rails.  The next step will be to cut the foam and do a layup to the floor.  Happy thanksgiving.

 Cutting out the drivers side floor for the frame rails.

Driveline / Frame Tube

Driveline tube and frame rail tube.  You can see the mark for the left frame rail.  For some reason the resin was very red?

Frame Updated:

The frame needed to be stiffened.  The frame was to flexible.  So I added a 1" tube just above the main 1.5" frame rail tubes.  It is plenty stiff now.  I am cutting the grooves in the body so the drive-line and frame rails have a spot.  I also took off the sub-frame above the rear suspension.  I am going to have a piece of steel fabricated so the shock mount is moved to a location so the frame will be sitting in the right location from the ground.  Lot's and lot's of details to work out.  But it is so relaxing and fun. 

Here is the wheel I have chosen for the front.  I hope to have them ordered soon.

Labor Day work on body and engine placement:

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Plenty of leg room

I had to move the engine back 8" so I would have room for the rack and pinion.

Body cut out for the engine so we could fit the rack and pinion in front of the engine.

Trunk lid closed.  I will need to adjust the hinges.  The left side is up .120" above the body.

Trunk lid mounted to hinges

Before trunk lid.

Finally mounted the hinges to the fiberglass body.

Updated Morgan Trike shots and video link

Great video of the Jay Leno taking a new Morgan Trike for a drive:

http://youtu.be/_CvVr9jU4I0

Hinges and Africa

After our team won in the soccer match. Football as they call in the rest of the world.

Here is the new ball we traded them.  I set the old ball down and a young boy from the village found it.  He was afraid I was going to take it back.  Such a small thing brings so much joy.  Playing soccer with these school children was one of the highlights of the trip to Kenya.

This was the ball the school children were playing with.

We played ring around the roses with these school children.  This was after we visited a Yehu meeting.  Excellent day in Kenya.

So I have not made a post for a while:  My wife and I were blessed to go to Africa and do some humanitarian work.  Above is the picture of the employee's of Coast Coconut Farms.  We did some Lean Training with the employee's and the Managers.  It was such a great experience.  They are Awesome people.  Thanks So much!

 

So I ordered some hinges and they are heavier than the trunk lid.  So I am attempting to fabricate something similar out of foam and fiberglass.  If it does not work then I will attach the steel to the fiberglass body...

Trunk Progress

You can see the tabs which will hold the trunk.  I will add them all the way around.  Then we need to mount the trunk hinges.

Rolling It out of the Garage

 Check it out.  I rolled it out of the garage using hydraulic jacks in the front.  I need a couple of wheels and coil over shock mounts and then I can roll it in and out as I continue the project

Passenger side:  We are going to make a door on this side. 

Trunk Lid

Trunk lid:  We had to cut the outer skin and then sand down the foam.  Then the foam had to be sanded to make a smooth transition from the outer skin and the inner skin.  Cotton filler was used to fill in the voids and then the fiberglass was added.  Super strong.  Next will work on the trunk portion.

Cuttin out the Trunk:

Jared helped me cut out the trunk!  He did a super job.  The teeth were gone on the saw blade.

 Right view:  Nice big trunk.  Easily fit a couple of duffel bags and a tent. Maybe even a Coleman stove.

Here is the trunk closed:

Car Tire replacement for motorcycle tire

Car Tire for Motorcycle Wheel
I would like to thank Karl at http://www.theroadscholar.net/ for giving me the information for a car tire replacement!  Quote "However, one person recently found that he could fit a 195/40-17 tire
directly onto his 5.5" wide stock BMW rear rim and have it clear his
swing-arm on the same bike.  He is running a sidecar."

Engine Mount:

Engine mount.  I used the rear part of the frame from the motorcycle (which has the VIN # on it).  I will weld on some additional cross support from a-arm to a-arm and then we can start wiring.  I have to cut some additional material from the body and fit it again and then mount the body to the frame.  It is coming along fine.

Body Fit and Engine Placement

 Body placement:  The body was a tight fit.  I will have to remove some additional body so that it fits better.  This will also allow for more clearance between the rear tire and the wheel well.  Very close from paper to fabrication. 

 Rear fender placement.  I am going to add some additional mounts to the frame and rear swing arm box.

Engine placement:  The K1200RS engine is huge!  I will fabricate the engine mounts next and also the rack and pinion steering.

Frame

 Spot welding the frame together.   It is good when a plan comes together!

Body support mounting points.  I will hopefully get some time to flip the frame and finish welding this week and then look at mounting the rack and pinion and then the engine and rear end. 

Fabrication of Frame

 Front a-arm suspension fabrication.  More to come.

 I finally got my all my sheet metal parts and I have been welding all day.  I am just positioning all of the pieces and will come back and weld them later.

  

Had a friend weld on an aluminum plate to support the open aluminum bike frame.

Cut out the fiberglass so the motorcycle frame portion has a spot to go.