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  1. #1
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    Default Track bike trailer build.

    Here is the evolution of years of plans to build a trailer specific to my needs so will share the build as it progresses.


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  3. #2
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    traile11.jpg traile12.jpg traile13.jpg Working to VSB1
    Flat top
    Very Light trailer (TA)- A Single axle-axle trailer with a GTM not exceeding 0.75 tonne.

    Goals/specs are

    Weight-
    Tare; 180kg
    ATM; 500kg +180kg +68kg = 748kg.
    GTM; 500kg +180kg = 680kg
    *5-10% of total weight as ball weight is 34-68kg (ie 1 OR 2 bikes)
    *20kg minimum unladed ball weight is required.
    40mm square axle LM brgs 1000kg load rating
    5 leaf spring assy 680kg per pair set
    50mm 3 bolt on coupling 2000kg
    8mm trailer chain 1600kg
    15x7JJ alloy wheels, HQ stud pattern, DOT-T
    Load rating - 950kg
    Max inflation - 290kPa
    195/55-15 tyres 85V- 515kg load rating

    Height-
    450mm maximum deck height
    Numberplate 372x136mm
    195/55-15 tyres diameter- 595.5mm, Radius 297.75mm
    Must be able to unload and load by one person in the least amount of time, as space in the pitlane is crowded at the start and finish of the day, 100+ bikes have to go thru this process, similar to a boat ramp staging area, but generally motorcycle racers are far more helpful than your average boat ramp cowboys and if done correctly its a seamless operation then taken out of pit lane for the next entrant and their crew.
    The trailer will also double as a workbench while away from the track helping the endless preparation involved in the sport.

    Width-
    1800mm wide overall at the maximum, two bikes will fit inside the wheel arches, and the car wont know its there, and squeeze into any parking space.
    Left to right motorcycle c/c - 750mm.
    1650mm Axle tip to tip
    1234mm outside chassis/outside chassis
    1554mm Hub face/hub face (fitted and measured)
    110mm Backspace (Bare rim)
    100mm Frontspace
    1334mm Inside rim/Inside rim
    50mm Rim to chassis clearance
    50mm Tyre to chassis clearance with 195 tyres.
    (41mm with 205/65-15 tyres which wont be used)
    1754mm Outside rim/ outside rim.

    Balanced-
    3400mm overall length
    1200mm Drawbar length
    Longer drawbars tow better and are easier to reverse,
    ~1200mm front loadspace
    ~1000mm rear overhang
    Axle placement is 25mm rearward per 600mm load area as a rule of thumb for a box trailer but this is a flat top so more tuneable, but will be between 91.66 and 100mm.
    *motorcycles have an average of 50/50% weight distribution and the front wheel chock and rear tyre down points can be adjusted to suit 1 bike vs 2 bike carrying


    Rear Tyre down mounting points ideally 50mm forward of motorcycle rear axle, and between 750- 900mm apart for each bike.

    600cc = 1375 wheelbase, 1990mm total.
    250cc = 1370 wheelbase, 1977mm total
    1000cc = 1410 wheelbase, 2021mm total

    Race bike handlebars range from 690-735mm wide
    Footpegs range from 510-560 wide

    Well balanced trailers are safer, have better high speed handling, more efficient to tow, and make all the difference.
    Average return trip to the local tracks are 800-1200km, always night driving at highway speeds,
    National rounds are 7000-10,000km return, so the trailer has to be set up correctly.

    Budget-
    Probably double the $1500 initially planned, paid that in hire fee's alone this year.

  4. #3
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  5. #4
    Yonnee's Avatar
    Yonnee is offline Trailer Bloke & Mild Mannered Moderator
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    Nice looking design. Looking forward to seeing the build.
    Too many projects, so little time, even less money!
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  6. #5
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    Quote Originally Posted by Yonnee View Post
    Nice looking design. Looking forward to seeing the build.
    Thanks, scratched my head for years as to why/how a trailer cant/can be built in the one horizontal plane, There is some forces to be considered but finally cracked it when I worked out how to sink the drawbar into it after the frame is built. and how i'm going to support & secure the load (motorcycles) Its just alot more work, but the customer is me so it doesnt matter.

  7. #6
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    Drawbar & outer chassis rails 75x50x2.5mm x8m, 4.580kg/m = 36.64kg $69 +GST
    TyreDown crossbrace, front beam, front corners, rear corners 75x50x2mm x8m, 3.72kg/m = 29.76kg $59 +GST
    Motorcycle supports, frame pcs, front wheel crossmember 50x50x2mm x8m, 2.93kg/m = 23.44kg $45 +GST

    Total steel uncut 89.84kg.
    Frame steel as drawn 77kg.
    TOTAL steel cost - $201.18

    Each 8m lenght of Steel had to be cut in half for transport, so I like to mark off each piece thats used, saves cutting from the wrong length. traile14.jpg

    The truss and some short lightweight cross braces are 20x20x2mm and 25x25x2mm from the scrap pile from other projects.

  8. #7
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    Purchased 12/11/13-

    5 leaf spring assy $92.10
    Hub assy HQ std $63.87
    U bolt set $$24.31
    5 core electrical flex 8 metres $17.70
    2 core electrical flex 8 metres $9.42
    Wheel nuts 7/16" domed for alloy $13.20 (only 6 available 7 more on order)
    Coupling 50mm snap bolt on 2t $30.04
    Plate suit AO112 coupling $10.41
    Compliance plate $3.53

    TOTAL- $259.08

    Purchased 13/11/13-

    Mudguards S/A suit 13/14" wheel $53.56
    8mm Trailer chain 1600kg 1.2m $19.78
    7 pin plug Metal $5.50
    1/2"x2" UNF Bolt &nut grade 8.8 3off $3.43
    4 1/2"x1/2" UNF Bolt&nut grade 8.8 1 off $2.77
    Axle 1650mm 65" 40mm square $104.08
    10mm Dee Shackle Galv 2 off $2,97

    TOTAL $192.09

  9. #8
    Yonnee's Avatar
    Yonnee is offline Trailer Bloke & Mild Mannered Moderator
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    Quote Originally Posted by Aufitt View Post
    Purchased 12/11/13-

    Hub assy HQ std $63.87
    What wheels are you running with HQ pattern?

    You do know that Commodore stud pattern is different to HQ...?
    Too many projects, so little time, even less money!
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  10. #9
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    Quote Originally Posted by Yonnee View Post
    What wheels are you running with HQ pattern?

    You do know that Commodore stud pattern is different to HQ...?
    NEVER fit Commonwhore wheels to HQ/Chev stud pattern, they might slip over the studs but chaos will eventually happen!

    traile13.jpg traile15.jpg 15x7JJ Challengers
    Purchased new 1997 from Performance wheels (SA) $720
    (HJ V8 1 Tonner, a mishap means Ive had 3 earmarked for this trailer for the past 15 yrs)
    Globe castings, drilled to HQ stud pattern on the production line.
    only the 15x7 came with rivets to look like Simmons B45 copies.

    DOT-T
    Load rating - 950kg
    Max inflation - 290kPa
    WIA 8P
    Offset(ET) - 8mm
    Backspace - 110mm
    Frontspace - 90mm
    Wheel"Face" - 381mm/15" (specs)
    Rim outer Diameter - 415mm (measured)
    Rim outer width - 200mm (measured)

  11. #10
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    De-burred Inner brg seat lip,
    Dressed damaged (they must throw them round the factory) seal faces with P100 emery working down grades till acceptable.
    I may fit oil bath Durahubs one day, but had enough experience with boat trailers to know that seal face and lubrication is the weakest link regardless of brg size.
    Cleaned swarf from split pin holes and threads,
    Swapped castle nuts over for same feel,
    Dressed axle flats and chamfers with P60 on 1/3 sheet sander and gave it a wipe with acetone.

    Marked centres 825mm in from tip (centre) with square.
    Checked inner brg face measurements (spot on)
    Checked high sides (bow) +2/1000mm & +1/1000mm and marked with tape.
    +2mm is TOP of axle
    +1mm is REAR of axle
    This determines LHS & RHS so marked each end with tape.

    Checked outer brg races (came fitted), cleaned hubs with acetone, lightly oiled brgs & races.
    Inner- KOYO Japan Hi-cap LM67048
    Outer- KOYO Japan Hi-cap LM11949
    Fitted Hubs to axles without seals, covered and taped (so I can dummy fit everything during the build)
    Fitted wheels to hubs (found one hub runout not too good, will swap it or keep as spare)
    Chamfered sharp edges off Fishplates
    Added 12mm flat washers to Ubolt nyloc nuts.
    bolted springs & axle locators equal to middle of planned chassis rails.

    Will need this later on. traile16.jpg traile17.jpg

  12. #11
    Yonnee's Avatar
    Yonnee is offline Trailer Bloke & Mild Mannered Moderator
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    Quote Originally Posted by Aufitt View Post
    NEVER fit Commonwhore wheels to HQ/Chev stud pattern, they might slip over the studs but chaos will eventually happen!
    Good to see.

    I've seen too many over the years where Commodore rims are fitted to early Holdens as well as trailers, and it's just a recipe for disaster.

    Looking good.
    Too many projects, so little time, even less money!
    Are you a registered member? Why not? click here to register. It's free and only takes 37 seconds! Doing work around the home? Wander over to our sister site, Renovate Forum, for all your renovation queries.

  13. #12
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    Now the fun stuff can begin.


    Using two dropsaws,
    one bench mounted with feed rollers set to cut 90' degrees, and the other for angles, this saves time, helps accuracy, and cutting disc wear on the straight cuts is not an issue.
    Marking out is done with square and scribe.
    Where material has a seam, it's orientation is considered.
    If material has a slight bow, its marked (and can be used to advantage/ oriented the same/ or allowed for)
    Where a gap is required to avoid distortion and help penetration when welding, 1mm is given
    All pieces get de burred inside with a file, 1mm chamfer outside with 4" emery angle grinder discs, and clean out the swarf & deposits with a rag.


    Cut the 75x50x2 rear tyre down bar 1620mm wide,
    marked the centre, and outer bike rails 750mm apart,
    Three 50x50 cutouts made drilling 8mm in corners, dropsaw for the vertical cuts, and carefully cut the remaining material out with 1mm cut off disc on angle grinder.

    Set the trestles up horizontal, parallel, and the correct distance apart with spirit level and measured, as they will stay there the whole build. (used 1mm/2mm/3mm grinding discs are ideal packers as NO concrete is ever level).

    Cut the centre and outer bike rails from 50x50x2,
    Allowed for the 40mm shorter Numberplate/centre ramp recess of the cente rail, its length determines where the front X member will be,
    The outer rails will be cut shorter once the drawbar is marked.
    Cut the two motorcycle front wheel crossmembers from 50x50x2 325mm

    With the frame upside down, and set up parallel, square, measured diagonals, and all dimensions as per the plan, it was clamped and tacked in the right places.

  14. #13
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    Turned the frame over, clamped and tacked a temporary 50x4 flat bar on top of the rear tyre down bar (will be removed later)

    Made the tail section of the trailer by marking it out on a workbench upside down.
    Set the cutoff saw to cut exactly 67.5' degrees which will make the 45' degrees required.
    75x50x2mm middle piece where the Numberplate sits is 372mm wide and recessed 40mm
    75x50x2mm spacers will mount the small LED numberplate lights.
    50x50x2 outer pods are 310mm wide (just enough for the universal folding ally bike ramps), central to each outside bike, and will have recessed LED Tail/stop lamps which suit requirements (600mm apart & 400mm in from widest part of trailer)

  15. #14
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    75x50x2.5mm Chassis rails lying flat (chasing lowest ride height without going to drop axle or IRS), 1234mm outside/outside to give 50mm chassis to rim.
    25x25x2 outer bike rail to chassis cross braces.
    25x25x2 inner bike rail to outer bike rail cross brace at front
    20x20x2 inner bike rail to outer bike rail at rear,
    These provide strength in the right places, not too heavy, and enough to support 2.5mm ally treadplate.

  16. #15
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    Turned upside down again to make the truss for the rear tyre down bar.
    Unlike the old way we used to destroy motorcycle suspension, forks, seals and shake the #### out of the bike by tying bikes down on the suspension with tiedowns, ratchet strapping down the rear tyre is far better for the bike, but not the trailer.
    Since I'm chasing the lightest build with the maximum strength, this simple truss is better than going to heavier material or deeper channel.

    20x20x2mm RHS, a slot cut where it angles upwards to meet the underneath of the tyre down bar.
    20x20x2mm spacer blocks, under each bike rail, 30mm long, placed 4mm from the front edge for strength.
    The tension from the straps pull slightly rearwards.

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