The Edge Products PO Box 292 Karrinyup WA 6018 Ph: (08) 9249 5886 Fax: (08) 9249 9521 THE EDGE PRODUCTS STATEMENT OF COPYRIGHT, OWNERSHIP & REPRODUCTION This set of offroad vehicle plans has been designed, developed and produced by The Edge Products for the home builder to make their own quality offroad vehicle. This set of plans has wot been produced for any individual, individuals or business to make financial and/or commercial gain in either reproducing the plans, components or complete vehicles. All rights reserved, the drawings and designs within this set of plans es individual parts, sub-assemblies or complete vehicles are expressly copyrighted to The Edge Products. No paris of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical photocopying, transmitted via the World Wide Web, recording or otherwise, without the written permission of The Edge Products. The Edge Products reserve the sole right to sell and reproduce the said nlans and sole right to manufacture parts and complete vehicles f:om these plans for financ’ and/or commercial gain, Legal action will be taken against any individual, individuals, or business mai financial and/or commercial gain from reproducing either these plans, compo: vehicles derived from these plans and designs. ents OF This set of plans gives the owner the right to manufacture their own vehicle for the purpose of recreational use only, which as a finished product is not permitted to be used to detive income unless written permission is given from The Edge Products. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as. possible, The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © The Edge Products 1997GENERAL INFORMATION ON PIPE & R.H.S. CONVERSION FACTORS [_mm | age IMPERIAL COLOUR CODE WALL THICKNESS mm inch Extra light, Yellow end Light Blue band Medium Heavy Red band White band Extra heavyUnits of Length: km x 0.6214 = mile i m x 3281 = ft Prefixes for Units: am « tere i Prefix Symbol Power mega M x 7,000,000 kilo k x 1,000 . . eat : x oot Units of Torque: milli m x 0.001 Nm x 0.1020 kgm micro # x 0.000001 Nem x 0.7376 ftlb Nm x 8.951 inl kgm x 9.807 Nm kom x 7.233 felb Units of Mass: kom x B6.80 int kg x 2.205 b 3 x 0.03527 = oz Units of Pressure: kPa X 0.01020 = — kg/em? kPa x 0.1450 psi L x 0.2642 gal (US) kPa x___0.7501_= _emHg L x 0.2200 = gal (imp) kg/em? x «98.07 kPa L x 1.087 = qt (US) kgfem* x 14.22 = psi L x 0.8799 = gt (imp) emHg x 1.393 kPa L x 2113 = pint (US) l x 1.816 = pint (imp) mL x 0.03381 = oz (US) . mL x 0.02816 = oz (imp) Units of Speed: me x 0.06102 = cuin ken/h x 0.6214 = mph Units of Force: Units of Power: N x 0.1020 = kg kw x 1.360 = PS N x 0.2248 = Ib KW. x 1.341 = HP. kg x 9807 = N PS x 0.7355 = kW kg x 2205 = lb Ps x 0.9863 = HP Units of Temperature: 9°C+4O) gy op SUF HAO) gyaeg 5 3 F 4 2 0 we 22a 40 60! 89 100i 120 140 160 {190 200 {220 240! 260 2601, 300 320 ye Sh Pe Tt ttt Ht a | 00 20 14080 7 a9, ma saa aie ase °cSAFETY IMPORTANT: PLEASE READ THE FOLLOWING BEFORE DRIVING The Edge Products wish to advise in the interest of your enjoyment, some safety features which will enable you to enjoy driving your vehicle and minimise the risks to yourself and others. HELMET Always wear a good crash helmet, a full face helmet offers more protection than an open face. Remember to buckle up the chin strap, HARNESS On vehicles that have a full rollcage it is advisable to use a good quality 4 point hamess. Always adjust it to suit your body by first tightening the hip strap onto your hip bones (not your stomach). ‘Then tighten your shoulder straps. A car type 3 point hamess does not work well in a rollover situation as it does not Stop you slipping through the top. A 4 point harness as a minimum safety requirement is advised, a 5 point hamess is even better. EVE PROTECTION Itis advisable to wear either goggles or a helmet type visor. WRIST RESTRAINTS It is advisable to use some form of arm restraint to stop your arms flying outside the vehicle if it rolls over. Either buckle type wrist restraints or rolleage nets work well. People have broken arms or lost fingers from not using these safety items so take care, DRINKING, DRUGS & DRIVING Do not consume alcohol and drive any type of vehicle. Even though you may be away from domestic traffic and in an offroad area, drinking and driving is dangerous to both yourself and others. The nature of offroad driving means the terrain is demanding and unpredictable so you need to be alert and focused on ‘what you are doing. Drugs and alcohol dull your senses and concentration. SHARP OBJECTS Make sure the interior of your vehicle is free from sharp objects that may come in contact with your body. ‘Any areas such as rollbars or chassis structure that are close to your body should be padded to prevent bruising or injury. RADIATORS & EXHAUST SYSTEMS Take care with radiators and cooling systems, if a radiator is punctured or a cooling hose is split or comes loose you may get sprayed with boiling fluid. Anticipate what would happen in this event and make an effort to shield hoses and radiators from flying objects and to shield yourself from potential hot fluids if the cooling system failed. Fitting double hose clamps to hoses is a good safety measure, along with running hoses away from the driver area, Radiators can be shielded and ducted to deflect fluid if punctured and to stop debris from causing a problem. Exhaust systems should be directed from the motor out towards the rear of the vehicle in such a direction as to be clear of the driver’s compartment and so the driver when operating the vehicle cannot come into contact with the hot exhaust pipe. It is also a good idea to put a heat shield on the exposed exhaust pipe to prevent anybody burning themselves.FUEL TANKS & HOSES BRAKES ‘Good brakes are essential. Braking is relative to ‘Speed; the faster you go, the better ‘your brakes should be, Always maintain your brakes so that they are always in good working order STEERING Steering is an important safety area, without it you have lost control. Always make sure that steering Joints are in good condition and check for loose bolts, * Always make sure you are driving in a legal offroad driving area, Each state in Australia has designated offroad driving areas. Ifyou are unsure as to where the closest area to you is, phone your local shire or council and ask. If driving on private land always ensure you have permiscion frome the owner. * Remember the bushland of Australia is therefor everybody to enjoy. You have no more right to be there than anybody else, so always be careful and help other people out when you can, you never know when you may need help yourself. * Tread lightly, eemember bushland belongs to the animals not us. Try not to damage plantlfe, trees and the natural habitat of ous unique wildlife, ‘The more responsible you are, the better it willbe forall of us and the better an image forthe sport of offroading you will create, guaranteeing forall of us acceptance and respect from the general public DISCLAIMER The Edge Products (Foundry Holdings Pty Ltd), their agents or employees will not be held responsible for any damage caused by any of their vehicle designs to person or property The Edge Products make every effort to advise their customers of safety precautions and responsiblity and cannot be held responsible for the actions of an individual or individuals. The Edge Products cannot be held responsible for an individual's quality of workmanship or for the suitability of the finished Product in respect to safety or the performance an individual may expect from the said design in various terrain and conditions. Offroading is a dangerous sport because of the varying terrain and conditions that ‘may be encountered and although The Edge Products makes every effort to design a solid and safe vehicle, The Edge Products have no control ‘over how or where an individual chooses to drive their vehicle. The Edge Products makes every effort to supply quality components to its customers but will not be held responsible as to the way’an individual assembles, fits or uses said components or the way or manner an individual uses a vehicle.GLOSSARY OF TERMS Acetal ANC ANF BELLCRANK Bending BMS CAUPER Camber Angle Castor Angle cps CNC « ERW FABRICATING FLATBAR Nylon type bearing material manufactured by CADCO. Used as bushes and lightweight gears. American National Course - American imperial size of course thread. American National Fine — American imperial size of fine thread. Type of lever used to increase or decrease leverage and/or change a movement's direction. Tending to curve or bow. Bright Mild Steel British Standard Pipe - a thread type used on pipefittings. A division between one area and another usually sealed off by a plate. Computer Aided Design — objects that have been designed on a sophisticated computer software drawing package. Braking device that grips the diameter of a disc brake rotor to slow it down, usually hydraulically activated. The angle between centre line of tread and a vertical line drawn through intersection of centre line and ground line. Camber angle can be either positive or negative, in the latter case; the top of the wheel is nearer the centre line of the vehicle. Correct camber angle lessens bump steer. The angie between a line drawn through the kingpin top and bottom bearings or equivalent and a vertical line through the wheel centre inside elevation. Cold Drawn Seamless - (steel tubing) Grade 450. Computer Numerical Control — a system used to control automated machines using computer guidance. Centreline - symbol shown at the centre of some drawings. Electro Resistance Welded (steel tubing) Grade 200 ‘To measure, cut and weld to create a finished product from raw materials. Steel that is sold as flat lengths. . Inside Diameter — inside measurement of round objects. International Standards Organisation (metric) A half thickness-locking nut used mainly on rod ends.GLOSSARY OF TERMS KINGPIN LAY-SHAFT m mm MODULE. NB NPT NYLOC @ oD PcD PUSHROD RHS TOE IN, TOE OUT TORSION TRACK UNC UNF UNI-JOINT w WHEELBASE The pivot bolt or pin (or axis) in which the steering wheels of a vehicle tum about. A shaft which is driven by another. Metre - metric measurements. Millimetre - metric measurements. A self contained item, usually an assembly or parts to create a specific item. Normally used in combination with other units. Nominal Bore - classification given to some sizes of pipe. Very rarely is the pipe actually the internal size quoted! National Pipe Taper - American imperial size of tapered pipe thread. Brand name for a self-locking nut that uses a nylon insert to lock onto the bolt thread. Diameter - measurement for round objects. Outside Diameter - outside measurement of round objects. Pitch Circle Diameter - diameter of a circle in which holes are evenly spaced. A rod connecting one device to another to transfer movement. Rectangular Hollow Section The angle between a pair of wheels, a difference of measurement between ‘the tyre treads on the front and rear of the wheels at hub height. When the distance is greater at the rear, the wheels have “toe in”. It is normal to allow “toe in” of about 3mm to counteract the effect of wheel deflection. Twisting Effect The distance between the tread centres of the tyres on one axle, ie. the track between the rear wheels. Unified National Course — an imperial size of coarse thread. Unified National Fine — an imperial size of fine thread. A device used in rotating drive shafts to allow the shaft to move through angle changes and still rotate. Whitworth — British Imperial Course Thread The distance between front and rear axle centres,SIDEWINDER PLUS SOME TIPS ON CONSTRUCTING PURCHASE OF PARTS We strongly recommend purchasing a complete bike wreck, as many of the motorcycle parts can be used on the "Sidewinder". It is best to hear the motor running before you buy. Motorcycles suitable for wrecking may be bought through your local newspaper or insurance tenders for damaged bikes. To find out about tenders, ring any of the larger insurance companies in your area and find out where their holding yard is. You can then have a look and see what is available. You can also check your local newspapers for damaged or cheap motorcycles and check out the local wreckers. WIRING It is @ good idea to use the original wiring loom with the motor for ease of setting up the electrical system, Most motorcycle electrical systems are fitted with plugs and sockets for each component, e.g. coils, battery, regulator, motor ete. Follow the wiring diagram for your motoreycle and plug in the parts you need such as the ignition switch, coils, motor, battery etc. ‘You can fit the ignition switch next to the steering wheel, the battery in front of the motor (use the original bike battery box) and the coils can be mounted above or next to the motor on the upper chassis frame. A car battery could also be used in a marine type battery box that will fit behind the fuel tank. Any surplus wiring not needed can either be carefully disassembled or put in a sealed box. A motorcycle motor manual will come in handy for sorting out the wiring and setting up or repairing any of the bike parts SPROCKET & CHAIN We have found lower gearing than the donor bike suits the "Sidewinder" best. On average a rear sprocket with an increase of approximately §-10 teeth gives the "Sidewinder" quicker acceleration, but a lower top speed. We recommend a 14 tooth on the motor and a 50 tooth on the rear axle. The standard chain can be fitted but may need shortening, A chain tensioner is fitted to keep the chain tight at all times and allow for any slack which occurs with chain wear and stretch,SIDEWINDER PLUS EXHAUST ‘The exhaust pipes on the motor may also be used. The header pipes can often be swiveled on the head mount clamps and the exhaust pipes can then be positioned in the direction most convenient to exit the pipes out the rear to a muffler. We have found accessory mufflers work best as they give better performance and are smaller and lighter. BRAKES The "Sidewinder" can use a motorcycle disc and caliper on the rear axle. ‘The caliper mount you will have to custom make yourself to fit your caliper as all calipers are different. The disc will also require a mounting hub to affix it to the rear axle, If not using a second hand caliper The Eidge Products have a new caliper and mount available to suit the Sidewinder, (CAL-01 AND MHU-01). ‘The mounting hub for the disc will need a bore of 1 4” and a keyway 10 mm wide and 5 mm deep. The face of the hub will need to match your disc, The Edge Products have a standard disc brake rotor to suit, (DBR-02) which will bolt straight onto the axle using our MHU-01 Drive Hub. As for a master cylinder, you can use one from the foot pedal on a road bike. Again you will have to make a mount to suit and it should be Positioned between the pedal and the steering crossmember. The Edge Products also have a master cylinder (MSC-01) to suit the pedal boxes listed in these plans. A brake line between the master cylinder and the caliper is best made of a flexible stainless braided hose. SHOCKS The "Sidewinder Plus" uses monoshock road or trail bike rear shocks on the front. From 380 to 390mm eye to eye, The rear uses a trail bike or motocross monoshock, approximate length 450 mm eye to eye from 250cc to 650cc. The Edge Products also have new front or rear shocks available. WHEELS: The "Sidewinder" works best with ATV type wheels. For the front we recommend 10 x 5” wide rims and 21 x 7.0 x 10” tyres, and for the rear 8 x 8.5” wide rims and 22 x 12.0 x 8” tyres.(Fr » == SIDEWINDER TOOLS & EQUIPMENT Some basic equipment will be needed to fabricate the "Sidewinder" chassis. Here is a list of basic tools and equipment needed. WELDER A ‘Mig Welder’ is the most preferred as it can be used by most novice welders with the minimum of experience. More common is the ‘Arc Welder’, this can be used just as readily but needing more skill and practice to produce clean tidy welds. Other forms of welding suitable for construction are ‘tig’ and ‘gas’ welding (brazing). ‘The form of welding used depends on what your personally have available and what your skills are best Suited to. CUT OFF SAW Either a grinding type “drop saw’ or a ‘power hacksaw’ or ‘bandsaw’ may be used. If either of these are not available a ‘hand hacksaw’ or ‘angle grinder’ may be used with a sturdy vice. DRILL PRESS A drill press of 5/8” (16mm) capacity is the more suitable but you may use a hand power drill either in a drill press stand or on its own TWIST DRILLS And hole saws — a metric selection of drills and hole saws are required for boltholes and fabrication of chassis and suspension arms SQUARES A large fabrication square, a one metre rule and protractor bevel for marking out and setting up the chassis frame and angles will be required. A tape measure (metric) for measuring tube lengths. GENERAL HAND TOOLS Adjustable spanners, pliers, screwdrivers, angle grinders (4” or 5”) socket set, hand files, bench vice and a sturdy bench will all come in handy.SIDEWINDER STEEL MATERIAL LIST MATERIAL ary USED FOR 20x 20x 1.6RHS om Chassis bracing, Front suspension arms, Rear suspension arm 30x30x23 RHS | «Sm _| Lower chassis frame, nose uprights 40x 40x 2 RHS 18m Main chassis. 50x25 x2.5 RHS 1.6m | Rear suspension arm 100 x 50 x2 RHS 600mm | Pedal boxes ~ 20NB x 2.3 PIPE 2m Stub axles, gear shift tube, pedal pivots, Rollbar uprights 25NB x 3.2 PIPE 65m Roll bars, front arms, rear suspension arm. 76.1x1.6 FRW Tube 560mm | Rear swing arm. 25 x 6 Flatbar 320mm__| Gear lever, pedal boxes, chaintensioner 32x 6 Flatbar 1.7m | Pedal box mounts, Fuel tank mounts, front suspension arm mounts, Chaintensioner, rear shock mounts. ‘| 40x 6 Flatbar 14m___| Pedals, chaintensioner. 50x 6 Flatbar 18m Seat belt mounts, top front shock mounts, front suspension arm mounts, pedals, pedal box, rack mount. 75x6 Flatbar 230mm | Top.column mount, top rear shock mounts. 80x6 Flatbar_ 120mm | Rack Mount Base 32x 8 Flatbar 600mm | Stub axle cradles, steering arms. 65x 8 Flatbar 320mm __| Rear swingarm mount plate. 12mm 1030 BMS round bar 350mm __| Pedal box mount pin 16mm 1030 BMS round bar 900mm | Front & rear arm pivot pins 25.4mm, (1°) 1030 BMS 200mm | Rack bush, Front arm shock mounts 50mm 1030BMS Round Bar 60mm | Rear Hub Sleeves ‘60mm 1030BMS Round Bar 150mm | Rear Hub Sleeves, Rear Drive Hubs 22.2. x2 CDS Tube or 750mm | Gear shift lever, steering shall 22x 1 6ERW Tube 15.8 x 1.6 CDS Tube 700mm | Tie rod tubes. 40 x 40 x5 Angle 100mm Lower column mount. 14" 4140 PG H-T Bar 1200mm | Rear Axle 25mm Acetal bar (plastic) 300mm Stub bushes, Pedal bushes, gear shift bush 30mm Acetal bar (plastic) 400mm | Front & rear suspension arm bushes 50mm Acetal bar (plastic) 100mm | Chain tension rollers PLEASE NOTE : EXTRA MATERIAL HAS BEEN ADDED FOR CUTTING WASTE.PARTS LIST FOR “SIDEWINDER PLUS” sm QUANTITY | PART USED FOR i Chassis Chassis PAIR Front Suspension Arms Front Suspension arms 1 ‘Rear suspension arm Rear suspension arm 6 Suspension pivot bushes Front and rear suspension arms PAIR Stub axles Stub axles 4 Stub axle bushes ‘Stub axles PAIR Front whee! hubs Front whee! hubs, HT ot Torana Holden patter i Ford escort rack and pinion Steering 1 Holden Commodore steering coluran Steering column ‘Rack and Pinion mount ‘Steering rack and pinion mount PAIR Tie rod ends ‘Steering tie rod ends PAIR ‘Nolathane sway bar bushes ‘Steering column bushes (23mm) 1 Steering wheel Steering wheel, 3 hole mount z Steering rack boots Replacement rack and pinion boots 2 ‘Front suspension pivot pins Front suspension arm pivot pins 1 Rear suspension pivot pin Rear suspension arm pivot pins PAIR ‘Rear axle bearings Rear axle bearings (UC206 1 2°) 4 Rear axle bearing flanges Rear axle bearing mounts (PF206) PAIR Front shocks Front coil over shock absorbers 390mm eve toeve 7 Rear shock ‘Rear coil over shock absorber 450mm eye to eye Zora Pedals Throttle, 2x brake pedals 2or3 Pedal Boxes “Housing for Pedals [Tore ‘Brake master cylinders Master cylinders for font and rear | brakes [Tor2 Pash rod and elevis ‘Between pedal and brake master cylinders 1 Pedal pivot bar Front mount for pedal boxes | 1 Rear brake hose ‘Hose between brake master cylinder and caliper 1 Caliper (eat) ‘Rear brake caliper 1 ‘Caliper mount (rear) ‘Rear brake caliper mount bracket 2 Banjo bolts and crush washers Fits brake hose to master cylinder and | caliper 1 | Rear disc brake rotor ‘Rear brake rotor 240mm 8 2 Drive hubs "Mount hubs for rear dise and drive sprocket 1 Drive sprocket 50 tooth, 530 pitch rear axle drive | sprocket 1 Drive chain 530 pitch heavy duty chain 2 | Key steel 2 pieces 10x 10 key steel for rear axle drive hubs 1 | Chain tensioner ‘Chain tensioner and rollers Fuel pump _ Either vacuum (pulse) or electricPARTS FOR “SIDEWINDER PLUS” CONT'D.. 2 Fuel hose ‘6mm (1/4”) fuel hose between tank and | motor 2 Fuel filters Fuel filters in el hose line 1 Fuel tank Fuel tank i Fuel filler spout and cap Filler spout and cap to suit fel tank 1 Fuel outlet tap 12" BSP female ball valve type tap 1 Fitting 4" to 4" male BSP Fitting between fuel tank and outllet tap 2 Fitting 4" male x BSP 6mm tal ‘Vent pipe, fuel tap outlet 10 Hose clamps ‘Hose clamps to suit 6mm fuel hose PAIR Tie down straps uel tank tie down motor eyele type ‘mount straps i ‘Seat Racing type fibreglass bucket seat L ‘Throtile cable ‘Between throttle pedal and carbie 1 Throttle return spring Fitted to throtle pedal 1 ‘Air cleaner pod To suit motor carbie 1 Floor pan ‘2mm sheet of aluminium 600 x x1200mm T 4 point racing harness 4 point safety racing harness 1 Gear change lever Hiand gear shift lever 2 ‘Gear shift rod ends ‘MIO rod ends fot either end of gear | shift linkage 7 (Gear shift link rod ‘Between motors gear lever and hand shift lever T Clutch lever Motoreyele type, clamps onto hand shift lever 1 ‘Clutch cable Original bike clutch cable can be used 1 Mafiler For motors exhaust system 1 Battery Only needed for electric star, or electric fuel pumps or spot lights T Battery box For battery safety can be mounted behind fue! tank T Radiator ‘Only needed on water eooled motors 1 Oil cooler ‘Only needed on 4 stroke oil cooled motors 2 10x 5° ATW Rims (5 Stud) ‘Front wheel rims 2 8x85" ATV Rims (5 stud) ‘Rear wheel rims 2 21 x 7x10 Front max tyres Front tyres. 2 22 x 1200 x 8 Bearclaw tyres Rear tyres [4 Tubeless valves ‘To suit wheels 1 Bonnet ‘To protect driver from stones et. 1 Kill Switeh ‘To tum motor on and off. 1 Starter button switch Used for electric start motors“SIDEWINDER PLUS” NUT'S AND BOLTS [QUANTITY | Size USED FOR GB Mox20 Bok ‘Steering wheel ia ‘MB x 30 Bolt ‘Rear axle bearings, disc and sprocket mounts 6 M8 x 40 Bolt Steering column lower clamp, master eylindr/ pedal box mounts 4 M8 x 30 Bolt Fuel tank straps 5 MB x 65 Bolt Chain tensioner and tensioner mount | 2 ‘MIO x-20 Cap serews | Rear axle hub scotch key 4 MI0x25 Bolt Steering column bushes 4 ‘MIOx 10 Grubserews | Drive hubs 1 Mi2x75Bolt ‘Lower rear shock mount 1 [Mi2 x 165 Bolt Front stub axles 4 ‘4? UNF x2” Bolt | Top front shock mounts, dering rack Ge rod ends 1 V8" UNF x3 1/2” Balt_| Top rear shock mount 7 Nurs. _ 3 MG Nyloe nuts Steering wheel 2 MB Nyloc nuts Suit above bolts 4 MIO Nyloc nuts Steering column bushes — 6 MI2 Nyloc nuts Suit above bolts 7 4" UNE Nyloc nuts | Suit above bolts and te rod ends 2 "UNF Jam nuts | Tie rods 3 5/8” UNF Nyloc nuts _| Suspension pivot pins WASHERS é “mm zine plated Nat | Steering wheel washer a ‘Smm zine plated fat | Suit above bolts washer z TOmm zine phed Bat | Stearing column bushes washer 30 2mm zine plated fat | Sut M12 & ” bolts washer 6 ‘6mm zine plated flat | Suit suspension pivot pins ‘washer 2 10mm spring washers | Suit rear wheel hub scotch keys _ yDS AND ENDS T Small U bok (ai ik mount 32mm BSP water pipe) T Large U bolt (its | Rack mount 38mm BSP water pipe) 2 3.x 15 TER serews | Floor pan NOTE: EXTRA NUTS AND BOLTS WILL BE NEEDED FOR MOTOR MOUNTING. 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Fas TIVULSNY NUSLSIM dNANINYWM ‘Z6Z XO Od si9ngaoud 39Ga 3HL MYBLVTA 9xZe = IWRILVAL Gauinoau p anus issu SOV ANNOW MNVA Tans SAN! Gag tam St aad SIH we aan 10, q ozs a os oF o6rezSIDEWINDER PLUS To fabricate the front swing axles you will need a flat steel plate or steel table to work from. The size of this plate needs to be at least 600 x 250mm. STUB AXLE CRADLES First fabricate the stub axle cradles, These are made of 32 x 8 flatbar and must be welded square and accurate to the drawings. A tip here is to cut a spacer tube 123mm long and bolt this between the cradle end plates using a MI2 x 175 bolt This will space the end plates at the correct distance and allow you to check squareness before welding the backplate of 32 x 8 flatbar 123mm long Tack weld the cradle together before fully welding so it can be checked against the drawing. Now the steel plate comes in handy for setting up distances and angles, Refer to the suspension arm jig drawing for dimensions for the location of the pivot tube and stub axle cradle. A 12mm pin has been tacked in place at a distance of 532mm from the pivot tube and set at 6° castor and 20° camber. Now the stub axle cradle can be dropped onto the pin. You now have the correct distance between the cradle and pivot tube. Cut a length of 20 x 20 x 1.6 RHS to fit between the lower part of the cradle and the pivot tube. Cut the required angles on each end of the RHS with an angle grinder or cut and fit with a hacksaw and file. Tack the RHS into position sitting flat on the steel plate. All four sections of RHS can be measured and tacked in place by using this method. Remember - when it comes to making the opposite swing axle, the 12mm Pin has to be positioned on the opposite side After the arms have been completely tacked together, they can be removed fiom the plate and fully welded ‘The shock mounts can then be welded in at the required position. Set both of these mounts apart with a spacer tube and bolt and position squarely under the RHS frames. 19az ub\sop _]9251 SLongoYE 3003 3G savas aS SPRY ENS | sLonaoud 3903 FHL saan gals saata:d0. 2 zh T 2 oy. r| 3 a ter ae eb ‘mata ONS ava SaN3 a1awus- gauinoaa z avaiyis ex ze = TRAV Sa1dvuD Six ans U aauinbaa z NOT uuEZE x mar availa 8x ze 3 8 aHonidn s1avE9 8 aauinoay » eNOTUusy x avalvi ox Ze ‘Sana a1GvED aM Nl z i z z 7 : : STBYN3 OL NMOHS az 5 Xoklgdv senting a I AL 1d dv L| [> L a | 4 oF \, | rq q |of ubisap _ ]896! 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SaTOH wwo) sauHL “LINS 04 LaMDv¥a LNNOW v SMVIN O4 GaN TIM NOA Madi Iv9 GNYH GNODS v ONISN aI “(L0-1V9) ‘wadlTv9 anvuR INS 01 GaNDISaG Si LaMOVMe ANNOW UddrIv9 SIHL? LON sayuvug LTHE SIDEWINDER Fuel System ‘The Sidewinder has a large capacity fuel tank (approximately 2Slitres) to off set the weight of the motor. The tank is mounted on the left side of the vehicle. ‘The tank is fitted with baffles to prevent fuel sloshing around and causing weight transfer. MOUNTING ‘The most ideal way to mount the fuel tank is to glue compressible rubber strips on its underside between the chassis and tank, This acts as a cushion for the tank to sit upon. ‘The tank is secured by tie down type straps (2) to pull the tank down onto and compress the rubber. Small brackets can be welded to the chassis on either side of the tank to hook the tie downs onto. An electric fuel pump is fitted in front of the tank near the fuel outlet to suck fuel from the tank and supply it to the motor. If not fitting an electric fuel pump a vacuum pump (pulse pump) works very well. This type of pump ‘must be mounted close to the carburator. A vacuum pump requires no electricity, itis activated by either crankcase pressure or inlet manifold vacuum. If connecting to the crankcase breather it is best to install a teepeice at the breather. One branch goes to the pump, the other must be restricted to a very small hole. It is advisable to fit a fuel filter in this line and route the fuel line around the floor area behind the driver’s seat towards the motor. ‘Make sure that with the tank mounted, it does not come in to contact with the chassis and scuff or rub the tank. Make sure there is rubber between all contact areas. The electric fuel pump must be wired into the ignition switch so that with ignition on, the pump will start, and when the motor is killed so is the fuel NOTE: Never attempt to weld a fuel tank which has had fuel in it. Even when flushing, fumes still remain and can have the effect ofa small bomb if welding heat is applied. 78bh See Ubjsap__ |8661 SLONGOHe! 3903 HL GO] Gavewsayeeeee aav'mas nownstos wisn wee ate saan Tas i sexs AS sine wencon! “BLOO “WHIVELSNY NUGLSAM INVA Tang gy AaNANiuuvy ‘z6z XO Od = cow . $19Ndqo0u¥d 3903 3HL mala LNOUS MaIA don Fi aia ATINg AgaHS Siw wuz = Tv ‘aauindau b MNVL Tans QV B FLV 1a Wi, Wows Savi 3a NYO ‘Salvid BSaH4 ‘HSO1S T3N4 dois OL OINVA Tafa aH O1 GaLLId 3a NV SMBH NMOHS Sv S3ivid 31a3va aang GaNIVANOD S¥H 41 st INV GTaM OL LdWL1V LON Oa NOLLNYS Zz q n z I = T aSANnoW DINVE Tans AaUyRTTS 6681 SLONGOYd 3903 SHG) “gL09 ‘vrivadigny NUaLSaM ANANINYVM "Z6z XO Od S$19ngoud 3908 aH “aNd SISSVH9 4301 ‘aH 40 3qISiNo aH. HIM HSN14 G3NOLLISOd SMV SANNOW ¥NVA Tang SMV 3aISNI BMA 40 GN3 HOV NO “AI NIViga 01 doo7 BHL HONOUNA Gassvd 1108 0sXeWi NY's SANNOW MNVL 3HLNI'S3TOH 3H. HONOMHS ‘dassva Si d007 aH "SGNa aHi NO doOT lG3HOLILs v ONIAWS1 SdvaLS aH 40 SONS IaH4 Wows G3AOWSY auy SHOOH BHA Tana PNITIHdS @ INV AHL NITOH ¥ ONTAVEL 40 MSONVG aH LNOHLIM LoVvaWNI NY suOSaY OLMNYL aH SMOTTY SiHL "SavULS NMOG SIL 3444 279A9NOLOW OML AG NMOG Q13H SI MNVA JHA "UaEENY 40 SaPULS NO ‘ONILLIS SISSVH9 AHL 40 3GIS 1431 3HL ‘LON maa gals.ubjsap _ | 886! SLongous 3003 SHLO) roupan aan gu noanovoon sn ane seu : fatuny uous Au ete vo wmsene] “BLOO “WIIWVULSNY NUSLSIMA Nva woud Fas oS Seok cae! aNANIUUM "oz KO Od aad fossa so' saa s19nGoud 3903 3HL 3LV1d ¥aNDaHD WNININNTY Wws'z YO [| Taq WniNtny cauie = Tyna ‘ozuinoau ¢ va Wools oer et U 2 is 8 is KS f le SAZAIM HO SMaUDS Mad USHA ONISN ‘Ag SISSVH9 ad 40 3gISUaGNN aML ‘04 G3XI4 3a NVO NVddOOTS LON HTHE SIDEWINDER AMAOTOR SELECTION Why a Side Mounted Motor? The advantages of mounting the motor on the side of the vehicle include: > unobstructed airflow to cool the engine > easy access to the kiok-starter > compact short wheel-base vehicle which is easy to transport and handle Above all the main design feature is to enable a cheaper rear swing-arm to be used (rather than an expensive, complex independent rear), To make the swing-arm work efficiently with the motorcycles chain drive the motors sprocket must be lined up with the suspension arm pivot point. Making Your Selection ‘The most ideal motor for the SIDEWINDER is a compact single cylinder motorcycle engine. Generally trail/enduro and motocross engines are best suited because of their lightweight single cylinder and narrow crankcase construction. Four stroke motors have a better spread of power and torque over their whole rev range, this makes them more suited to off-road use, particularly boggy terrain such mud and sand dunes. A narrow crankcase design has the advantage of allowing the motor to be mounted closer to the centre of the vehicle. You don’t want the motor mounted too far out from the vehicles centre-line as this will tend to unbalance the “side to side” weight bias. Electric Start Motors Electric start is a big advantage, this feature can be found on most of the road/trail four-stroke models from 1990 onwards, two-strokes do not have this feature. Multi Cylinder Motors Do not fit multi cylinder motors under any circumstances, Twin cylinder two-strokes are OK as they are lightweight and reasonably compact. Three cylinder two-strokes, two, three and four cylinder four-strokes are all far too wide and heavy. Not only will these motors unbalance the SIDEWINDER they also lack low down power and torque. The worst case example is the range of 400ce four cylinder motors being imported from Japan secondhand. Models such as CBR400, FZ400, ZZR400, GSX400 all produce good horsepower between 10,000 ~ 14,000 rpm, but below this rev range they are as useless as a Honda 50! Do not be convinced by well meaning motorcycle wreckers that this type of motor is for you, steer well clear! Mounting the Engine ‘When positioning the motor, one hard and fast rule must be followed — the motors output drive. sprocket must be in line with the swing-arm pivot point, The drawing of the swing-arm pivot mounts shows two holes in each plate, ‘The reason for this is that each motor being of a different design has a different position of its drive sprocket. Having two sets of holes allows you to set up your motor to the holes that most suite the ideal position. 82