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Sidecar Velorex 560 - PART No.4 - Wheel suspension + main body holders 3D Printer File Image 1
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Sidecar Velorex 560 - PART No.4 - Wheel suspension + main body holders

jawarmaniak avatarjawarmaniak

November 4, 2024

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Description

Hope the 3rd part was fun for you :)

https://www.printables.com/model/888136-sidecar-velorex-560-part-no3-the-sidecar-body-and

As usual the model part consist a big parts but the very small also so pay attention to the description and attached pictures. As usual be extremely careful during the assembly itself and work slowly and cautiously.
If you manage to damage or break some part despite being extra careful you should "weld" it with a soldering gun rather than gluing it with super glue.

For today I prepared to you all connection rods for connection of the sidecar frame to the motorcycle.

If you will need more pictures for better understanding, you can see here:

https://www.rajce.idnes.cz/jawarmaniak/album/jawa-tisk

at first we start with the wheel suspension

Printing instruction:

  • holder - 1 piece, red PLA, 50% infill, 0.15-0.2 layer.
  • swing_fork - 1 piece, red PLA, 50% infill, 0.15-0.2 layer.
  • stopper - 1 piece, black PLA/TPU, 20% infill, 0.15-0.2 layer.
  • bearing_cap - 2 pcs, grey PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

  • Glue the stopper into the correct place on the holder.
  • Cut the M4 thread in the swing_fork and screw in the threaded rod with a length of 58 mm.
  • Insert 2 pieces of the bearings No. 685ZZ into the holder.
  • Cover the bearings with the bearing_caps.
  • Slide the swing_fork.
  • Secure it with a M5 bolt and low nut.

 

at second we can complete the shock absorber 

Printing instruction:

  • dumper_body - 1 piece, red PLA, 40% infill, 0.15-0.2 layer.
  • dumper_eye - 1 piece, red PLA, 40% infill, 0.15-0.2 layer.
  • dumper_top_hinge - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.
  • dumper_bottom_spring_stopper - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.
  • dumper_cover - 1 piece, black PLA, 100% infill, 0.15-0.2 layer.
  • dumper_cap - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

  • Slide dumper_cap on the M2.5-30 DIN84 screw.
  • Screw the screw into the dumper_eye so deeply that the gap between the head of the screw and the dumper_eye is 25mm. You can fix it by the super glue if you want.
  • This assembly insert into the dumper_body and glue the dumper_cap on the dumper_body - or better - weld it by soldering gun.
  • Bend a ring from a piece of wire with a diameter of 1 mm, which you thread into the groove in the dumper_body. You can choose which groove you choose. If upper, the shock absorber will have stronger springs.
  • Thread the dumper_bottom_spring_stopper onto this ring. Slide the spring and dumper_cover. Use dumper_top_hinge to fold the whole thing.
  • You can install the shock absorber assembled in this way into the wheel suspension by 2 2.5 screws.
  • All assembly screw on the sidecar frame by 4 M2.5-5 screws with nut.

 

at third we can complete the main body holders 

Printing instruction:

  • front_holder - 1 piece, red PLA, 50% infill, 0.15-0.2 layer.
  • front_catch - 2 pcs, red PLA, 100% infill, 0.15-0.2 layer.
  • rear_holder - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.
  • front_silentblock_insert - 2 pcs, grey PLA, 100% infill, 0.15-0.2 layer.
  • front_silentblock - 4 pcs, black PLA/TPU, 100% infill, 0.15-0.2 layer.

If you have MMU unit, you can print next 2 part together as 1 part. If not you need print this parts separately and glue together after print.

  • rear_silentblock_01 - 2 pcs, black PLA/TPU, 40% infill, 0.15-0.2 layer.
  • rear_silentblock_01 - 2 piece, grey PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

  • Glue 4 psc of the front_silentblock into the front_holder and 2 pcs of the front_silentblock_inserts.
  • Slide the front_catches and screw it by M2.5-12 screws wit nuts.

 

Now you can complete the sidecar and screw it to the motorcycle 

 

Printing instruction:

  • frame_silenblock - 2 pcs, black PLA/TPU, 30% infill, 0.15-0.2 layer.

Assembly instruction:

  • frame_silenblock glue into the frame.
  • Both rear silenblocks screw into the frame by M2-14 screws with nuts.
  • Connect the sidecar frame to the motorcycle as shown.
  • Make the front wheel from the 7th part of the motorcycle building with the complete brake shield. https://www.printables.com/model/810134-project-jawa-cz-kyvacka-25035302-part-no7-wheels This wheel slide on the threeded rod on the wheel suspension and screw it by the low M4 nut with shim.
  • Cut from a piece of the rubber 1-2mm thick the inserts according the front_holder and the rear_holder. 
  • The front holder of the body and the rubber insert screw on the main body assembly by 1.6mm screws.
  • At the rear side place the rear holder with rubber insert and from inside slide two 2.5-7 screws.
  • This assembly install on the frame of the sidecar and srew it by 4 psc of the M2-4 screws with nuts on the front side and by 2 M2.5 nuts on rear side.

 

And.. that's all for now :)

Bill of material:

  • 8x nut M2
  • 12x nut M2.5
  • 5x low nut M4
  • 1x low nut M5
  • 1x shim 4mm
  • 1x screw M1.6-5 mm
  • 4x screw M1.6-7 mm
  • 4x screw M2-4 mm
  • 2x screw M2-10 mm
  • 2x screw M2-14 mm
  • 4x screw M2.5-5 mm
  • 2x screw M2.5-7 mm
  • 5x screw M2.5-10 mm
  • 3x screw M2.5-12 mm
  • 1x screw M2.5-30 mm DIN84
  • 1x screw M4-20 mm
  • 1x screw M5-28 mm
  • 1x threaded rod M4-58 mm 
  • 2x ball bearing 685ZZ (5x11x5)
  • 1x compression spring 15/1.5-55 (In the Czech republic avaliable here: Pružina vinutá - tlačná - D/d = 15.0/1.5 mm L=55 mm - pozink. | Mateza.cz )
  • rubber plate 1mm thick approx. 120x30 mm
  • approx 30 mm of the steel wire of the diameter 1mm
  • complete front wheel assembly of the motorcycle avaliable here: Project JAWA-ČZ KÝVAČKA 250/353.02 - PART No.7 - Wheels od autora jawarmaniak | Stáhněte si zdarma STL model | Printables.com
  • superglue

I hope you had fun during building and everything went smoothly.

You can look forward to the next part. The 5th part is under progress right now ;)

The 5th part is available here: Sidecar Velorex 560 - PART No.5 - Interior od autora jawarmaniak | Stáhněte si zdarma STL model | Printables.com

License:

Creative Commons — Attribution — Noncommercial — Share Alike

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