Broken Sidecar Frame

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cookiemech
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Broken Sidecar Frame

Post by cookiemech » Thu Jan 16, 2020 12:37 pm

I'm glad my friend Ed stopped over this morning for coffee. As usual, we repaired to my garage afterward since he likes to see what I've done since his last visit. I pulled the Ural out from its spot next to the BMW R100 I've been working on, so he could see the R100. For some reason, as I stood talking with him, I shook the left handlebar on the Ural, and noted that the sidecar was bobbing up and down, which I would not expect. This is the reason:
broken frame from left rear.jpg
broken frame from right front.jpg
Geez! Two days ago I had it out for a nice 70 mile drive and certainly hit speeds of 55 to 60 mph. That could have gone very badly, I think.

I know it wasn't broken a week ago when i flushed and bled brake fluid all around, as I was under there.

Anyone have experience with this particular failure? This machine has never been off road or subjected to anything unusual, and has roughly 8000 miles on it. My friend Chuckie, a master welder with 45 years experience, is stopping over tomorrow to see it.
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1982 BMW R100T
1994 BMW K75RT
1995 BMW K75/3
2009 Kawasaki KLR 650
2017 Harley-Davidson Road King
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Re: Broken Sidecar Frame

Post by Snakeoil » Thu Jan 16, 2020 12:51 pm

:lurker:
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Re: Broken Sidecar Frame

Post by chaos2 » Thu Jan 16, 2020 3:12 pm

Albuquralque had a 2014 where the snowman mounts broke off the frame, but the frame remained intact.
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Re: Broken Sidecar Frame

Post by Mr Wazzock » Thu Jan 16, 2020 3:21 pm

Feck! :o
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Re: Broken Sidecar Frame

Post by Wildhorse Cafe » Thu Jan 16, 2020 4:04 pm

Wow! How are your welding skills?
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Re: Broken Sidecar Frame

Post by cookiemech » Thu Jan 16, 2020 4:07 pm

I am confident about my welding skills so long as the piece isn't "mission critical". (I've done lots of autobody work and built cars for nieces from wrecks.) However, my friend Chuck is coming over tomorrow morning to look at it. Chuck has been a welder for a living for the past 45 years. I TRUST Chuck's work!
1982 BMW R100T
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2009 Kawasaki KLR 650
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Re: Broken Sidecar Frame

Post by Tomcatfixer » Thu Jan 16, 2020 4:35 pm

That is an impressive failure, the likes of which I have not yet seen! Looking forward to seeing images of the repair.
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Re: Broken Sidecar Frame

Post by stagewex » Thu Jan 16, 2020 4:38 pm

Never saw anything break like that and you say you don't ride off-road? That's certainly a good thing!
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Re: Broken Sidecar Frame

Post by ReCycled » Thu Jan 16, 2020 4:39 pm

That's a new one to me.

At first glance I thought it was going to be the snowman mounts, a known failure point... might as well have Chuck look at them too :)
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cookiemech
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Re: Broken Sidecar Frame

Post by cookiemech » Thu Jan 16, 2020 4:41 pm

Yes, Chad, I am as well. My concern is that if it happened at this spot, will it happen elsewhere? I didn't have any "event" that should have caused this, no significant pothole (no bent rim or blown tire).

Note that during the winter of 2018/2019, I had EVERY nut, bolt, fastener off this machine and EVERY painted piece was media blasted, shot with epoxy primer and single stage urethane, and I put it back together. So geez, not like each piece hasn't been handled and examined . . .

I'm the wrong kind of engineer here (electrical, not metallurgical) to understand this failure. Maybe the three cracked aluminum rims should have been some sort of clue?
1982 BMW R100T
1994 BMW K75RT
1995 BMW K75/3
2009 Kawasaki KLR 650
2017 Harley-Davidson Road King
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Re: Broken Sidecar Frame

Post by cookiemech » Thu Jan 16, 2020 4:42 pm

"Snowman mounts"? Are those the welded-on points with knobs on them that are part of the motorcycle frame?
1982 BMW R100T
1994 BMW K75RT
1995 BMW K75/3
2009 Kawasaki KLR 650
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2017 Harley-Davidson Road Glide Ultra
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Re: Broken Sidecar Frame

Post by sKiZo » Thu Jan 16, 2020 7:12 pm

"Snowman" refers to the rubber cones that soak up shocks to the car body.

And yes, I'd call that "mission critical" and leave the fix up to a pro, and add additional strengthening with both inner and outer tube reinforcements. Lots of rust evident inside the broken tube too, so I'd do some serious digging to find out how water was getting inside.

And ya, I'd worry about the rest of the frame too. Bad batch of steel? I'd give the whole sidecar a close inspection, and hope for the best.
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Re: Broken Sidecar Frame

Post by harryball » Thu Jan 16, 2020 7:34 pm

Just wow. Something new to be paranoid about.
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Re: Broken Sidecar Frame

Post by jeffsaline » Thu Jan 16, 2020 8:42 pm

My long distance guess is the failure is from the assembly welds and is in the heat affected zone (HAZ) of those welds.

I'll venture if I was fixing this frame I would probably put a piece on the inside of the frame for alignment and strength. After that was in and welded I would probably add a piece to the outside of the frame on at least two sides.

Maybe consider buying a lottery ticket as it seems you got lucky with this.

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Re: Broken Sidecar Frame

Post by cookiemech » Thu Jan 16, 2020 8:55 pm

I will mention this to my welder friend tomorrow. Thanks!
1982 BMW R100T
1994 BMW K75RT
1995 BMW K75/3
2009 Kawasaki KLR 650
2017 Harley-Davidson Road King
2017 Harley-Davidson Road Glide Ultra
2017 Honda CB1100EX
2020 Ural Gear Up

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