Building a Sidecar the Harley-Davidson Way
Revisit this 1920s brochure explaining how H-D made sidecars at their Juneau Avenue factory.
"You may know little about sidecar construction, and care less, but if you are going to be protected against "that tired feeling" after a long ride, someone has to give a lot of attention to this subject."
- Introduction to Building a Sidecar the Harley-Davidson Way
Building a Sidecar brochure cover (1920)Harley-Davidson Museum
The first Harley-Davidson™ sidecar was produced in 1915
In the 1920s, the company published a brochure highlighting the materials and processes used to construct the sidecars at the factory in Milwaukee. The brochure, as well as many of the original photos, remain in the archives. Enjoy these photos and quoted excerpts from the publication.
"Once upon a time the old "seat board" thrown across the wagon box and upholstered with a horse-blanket, was the only limousine of the immense majority of our people. Time and progress have given us the rapid and comfortable carriages of today."
The rotary cutter in action (1920)Harley-Davidson Museum
The rotary cutter in action. Each steel sheet is marked over a pattern. The expert cutter operating the cutting machine, follows the markings accurately and rapidly, making each part uniform in the thousands of Harley-Davidson™ sidecars.
Shaping the cowl (1920)Harley-Davidson Museum
Shaping the cowl, a process given the greatest precision. The beauty and uniformity of the car depend greatly upon this operation.
"The heavy weight sheet steel from which the body is cut, is chosen with utmost care, so that the foundation upon which the body is built may deserve the art and science which eventually mould it into the "thing of beauty" which is "a joy forever."
The beader (1920)Harley-Davidson Museum
The beader -- enclosing the quarter inch rod which re-enforces the bow of the cowl, insuring extreme firmness of the bow. The strength and stability of the cowl depends upon a firm bow support.
Cowl rods (1920)Harley-Davidson Museum
Bending the ends of the rods in the cowl. Also setting and testing the distance, which must be exact. These ends are welded to the re-enforcements on the sides, making a continuous steel rod support around the front.
"Instead of being satisfied with the common process of riveting, each seam is welded in a stitch-like fashion by the electric welder, which resembles a mammoth sewing machine. This electric stitching binds the body into one solid sheet of steel."
Electric welding (1920)Harley-Davidson Museum
Electric welding the metal cap across the front. The graceful curves and superior strength of the entire body rely upon proper cowl construction. The beauty of the cowl lines distinguish Harley-Davidson™ sidecars.
Merging cowl and sides (1920)Harley-Davidson Museum
Using the electric sewing machine, to blend the cowl and side re-enforcements into one continuous and rigid support. A great strain is often placed on the sidecar body and requires this strong support to make it stand up.
Installing braces and supports (1920)Harley-Davidson Museum
Three of the various processes of installing the braces and supports in the Harley-Davidson™ sidecar. These are features that bring the distinction of stability and long life, and prevent rattling and loose joints.
" The brilliant and even lustre of the finished sidecar is not an accident. It is the result of the most painstaking preparation of the surface for the enamel and varnish. Machine smoothing, hand filing, sand papering, steel wool rubbing and washing sends the car to the paint room absolutely free from every foreign substances, and ready for the atomizing paint spray."
Washing racks (1920)Harley-Davidson Museum
Washing racks. All parts are washed with a chemical cleanser and steel wool and afterward wiped and polished before going to the painting and enameling department, insuring a ready surface for painting.
Filing and polishing (1920)Harley-Davidson Museum
Hand filing and emery polishing: Putting the finishing touches on the body before going to the washing rack. Each body passes a rigid inspection at this point. All defects are corrected here.
Sidecar body sanding (1920)Harley-Davidson Museum
The bodies being sanded after receiving the prime coat of paint. All roughness is smoothed out and a suitable surface produced for the superior enameling with which each Harley-Davidson™ sidecar is finished.
Sidecar bodies in oven (1920)Harley-Davidson Museum
One of the baking ovens where the bodies are placed after each coat of enamel and baked for several hours at a temperature of 225°. This baking of the enamel accounts for the weather resistance of the body finish.
Spray painting sidecars (1920)Harley-Davidson Museum
Spray painting gives the body coat after coat of the smooth, velvety, olive drab color which has become so well known the world over. Between each of these coats the body undergoes the baking process.
"Between each of the four coats of paint, the car is placed in a mammoth oven, where it is baked for several hours at a temperature of 225 degrees. After the car has donned its beautiful dress of olive drab with black trimmings, it is ready to receive the upholstering."
Cutting sidecar interior (1920)Harley-Davidson Museum
Thirty layers of the Chase Leatherwove being cut to the upper pattern by an electric cutting machine. Chase Leatherwove is the renowned covering found only on luxurious automobiles and Harley-Davidson™ sidecars.
Electric sewing machines at work (1920)Harley-Davidson Museum
One section of the Electric Sewing Machines, where top coverings, curtains, windshields, etc., are constructed. Uniformity is the watchword. High grade material and careful fitting give the storm resisting pleasure of sidecar riding.
Assembling cushions (1920)Harley-Davidson Museum
One of the processes of building the Harley-Davidson® cushions. Note the great pressure so evenly distributed in the assembling operation. Ease and comfort in riding depends upon a firm out soft cushion structure.
"Built upon knotless, kiln dried oak frames is set the highest quality steel coil springs, interlocked and interwoven in such a way that sagging and "breaking down" are troubles never encountered in Harley-Davidson™ upholstering."
Sidecar interior construction (1920)Harley-Davidson Museum
Four stages in the construction of the arms and quarters. The arm is not being "stuffed" with hair or excelsior -- instead, the packing is sheet felt carefully rolled and pressed into a graceful and satisfying arm rest.
Attaching upholstery (1920)Harley-Davidson Museum
Screwing on the upholstery frames. Two dozen large screws hold the back and side upholstery to the flange of the body, and prevent any discomfort or annoyance from loosening of back cushions.
Bending tube for sidecar frame (1920)Harley-Davidson Museum
One of the first moves in building the sidecar frames - machinery for bending in the tubing. Each angle is framed with accuracy. These tubes are all bent hot to prevent cracking.
Sand-blasting (1920)Harley-Davidson Museum
Sand-blasting. Removing all borax and rust from tubing, making the surface chemically clean for filing and enameling, preventing any danger of scaling or blistering of enamel.
"The body and springs are built upon the principle of comfort combined with sturdiness. In the construction of the chassis, the big idea has always been a firm, true structure that guarantees perfect alignment while new and when old."
The final machining on especially designed fixtures (1920)Harley-Davidson Museum
The final machining on especially designed jigs and fixtures, making all holes and parts come in alignment with the motorcycle. The care in these operations overcome "misfits" at the finish.
Brazing (1920)Harley-Davidson Museum
Brazing. Non-oxidizing burners are used to prevent impairing the high grade of tubing used in building the Harley-Davidson™ sidecar. All joints are blended into the strength of a continuous steel rod.
Filing frames (1920)Harley-Davidson Museum
Filing of frames -- removes all superfluous brass which comes from brazing, leaving a smooth and even surface for enameling. This accounts for the beautiful, durable finish on the completed sidecar chassis.
"This snappy, refined body lounges gently over a chassis supported by extremely responsive springs which eliminate all memories of the primitive sidecar, and awaken the rider to the restful meaning of the Harley-Davidson way."
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