Promised swingarm mod

[DEEBS11]

And if you shim here, the big O-ring will not cushion the splines. Can't do that.

[DEEBS11]

Lots of issues to deal with.

[bikerphil]

Yeah, it does look like a lot more is involved. Would also need to shim the center and remove the same thickness from the outside of the hub. The ideal way would be to make a one piece spacer plate 2mm thick to fit against the wheel. Also, the fitment of the axle would probably be an issue. It may be easier to notch and reweld the swingarm after all.

[DEEBS11]

Thanks Phil. Well, I just ordered five 20x30x0.5MM shims to start off. Won't hurt to look at it. As far as the swingarm mod goes, I wonder how much clearance there is between the shaft and the inner swingarm wall area that is in question. In other words, how much can be cut down and re-welded without the shaft rubbing on the new patch. Maybe this job will need a minimum of shims plus a minimum of swingarm shaving. That's probably the way to go.

[bikerphil]

It's hard to say how much room is inside without actually cutting it open first. You could probably also cheat a little by moving the swingarm slightly off center to the right with the adjustment bolts to gain some additional clearance of the driveshaft.

[DEEBS11]

I like that idea because with a sidecar rig the swingarm can be offset and not make any real difference in handling,

[XSSIVEUS]

Folks, some really clever mods here. I want to provide an Engineering perspective:

I trained as a mechanical design engineer from one of the best Engineering schools in the world, and have managed many design engineers over the years. Anytime you modify a design, you may make it stronger or weaker, but always different. Cutting material away, makes a structure weaker. Period. Welding material introduces stresses not originally considered when designed. Maybe OK, maybe not. When I've looked at modifying someone's else's design, I've always considered how I could make the structure stronger, not weaker, and never just hoped it would be OK. Hope is a crappy design practice when safety is involved. The mod shown with support welded back in was a good idea though remember that welding also introduces new stresses into a design that can have unintended consequences. Just removing material and changing something's configuration (shape), is a roll of the dice.

All I'm saying is if you are going to make a mod that removes material and changes the original engineered configuration, see if you can add strength back in. It's your neck though I wouldn't do it for someone else and I sure wouldn't encourage someone else to do it unless a structural analysis was performed (something almost impossible unless you have SolidWorks or equivalent).

As Crazy Steve noted, you may want to keep an eye on signs of stress cracking and material fatigue because failure of the swing arm at highway speeds is probably not something you'll walk away from. Be safe folks.