Trailer PAV 40 - part No. 2

Hope the 1st part was fun for you :)

https://www.printables.com/model/1108824-trailer-pav-40-part-no-1

As usual the model part consist a big parts but the very small also so pay attention to the description and attached pictures. As usual be extremely careful during the assembly itself and work slowly and cautiously.
If you manage to damage or break some part despite being extra careful you should "weld" it with a soldering gun rather than gluing it with super glue.

For today I prepared to you all connection rods for connection of the sidecar frame to the motorcycle.

If you will need more pictures for better understanding, you can see here:

https://www.rajce.idnes.cz/jawarmaniak/album/jawa-tisk

at first we start with the wheel suspension

Printing instruction:

• spring_guide - 2 pcs, grey PLA, 100% infill, 0.15-0.2 layer.

• wheel_suspension_stopper - 2 pcs, black PLA/TPU, 100% infill, 0.15-0.2 layer.

After printing the parts, glue the wheel_suspension_stoppers on the spring_guide.

Slide the springs from pens on the spring_guides.

Insert the assembled suspension into the frame of the trailer and secure it from the back side with an M2-20 screw. It is necessary to screw the screw in all the way. See picture.

at second we can continue with side reflector glasses

Printing instruction:

• side_reflector_holder - 2 pcs, grey PLA, 100% infill, 0.15-0.2 layer.

• side_reflector_ring - 2 pcs, chrome PLA, 100% infill, 0.15-0.2 layer.

• side_reflector_glass - 2 pcs, clear red PLA, 100% infill, 0.15-0.2 layer.

• side_reflector_glass - 2 pcs, clear white PLA, 100% infill, 0.15-0.2 layer.

After printing the parts, glue the cut-off head M1.4-4 srews into the  on the side_reflector_rings. After that glue all side_reflector_glasses into side_reflector_rings. This will make 2 pieces of white and 2 pieces of red reflectors.

Screw these reflectors into the side_reflector_holders. The assemblies must be completed in a mirrored manner, so that on both sides there is red glass at the back, white at the front.

Finally, glue these assemblies into the open ends of the trailer frame (opened walls of the should be turned into inner side, closed ones to outer)

at third we can complete the wheel

Printing instruction:

• tire_1 - 1 piece, black PLA/TPU, 100% infill, 0.15-0.2 layer.

• tire_2 - 1 piece, black PLA/TPU, 100% infill, 0.15-0.2 layer.

• wheel_hub_1 - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

• wheel_hub_2 - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

• wheel_hub_3 - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

• wheel_hub_cover - 2 pcs, chrome PLA, 100% infill, 0.15-0.2 layer.

• mudguard_pav - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

The tire_1 and tire_1 glue together into one piece. Also wheel_hub_2 and wheel_hub_3.

Insert the tire on the glued wheel hub. Insert wheel_hub_1 and all sides screw together by 4pcs of M1.6-3 screws with nuts.

Slide the wheel_hub_covers from both side to covet the screws. Insert 2 pcs of the ball bearings 693EZO.

Screw the mudguard_pav to wheel fork by 2 pcs om M1.6-3 screws with nuts

insert the wheel, slide though the wheel threaded rod M3-40 and fix it by 2 nuts M3.

at fourth we can complete the body of the trailer

Printing instruction:

• body_L - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

• body_R - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

-  OR -

• body - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

• body_door - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

• door_hinge_holder_R - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.

• door_hinge_holder_L - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.

• PAV_leg - 2 pcs, black PLA/TPU, 100% infill, 0.15-0.2 layer.

You can choose which stls will print. If you print body_L and body_R you will glue together into one piece.

Cut off the head from 2 pcs M1.6-5 screws and glue them into door_hinge_holder_L and door_hinge_holder_L.

Glue 132mm piece of 1mm diam wire on the edge of the body_door.

On the both ends of the wire slide door hinge holders. Whole assembly screw the hinge holders with 2 pcs of M1.6 nuts from inner side of the body. The door should open easily.

Screw the body of the trailer on the frame witt 2 pcs M2.5-5 crews with nuts on the rear holder and 2 pcs of M2.5 srews on the front holder. The screws screw into the PAV_legs.

at fifth we can complete the door lock

Printing instruction:

• lock_insert - 1 piece, bronze PLA, 100% infill, 0.15-0.2 layer.

• lock_cover - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.

Glue the lock_inset into the lock_cover. Top surface should be in same lever.

Screw the lock assembly to the door assembly by 2 pcs of M1.6-4 screws with nuts.

at sixth we can complete the taillight

Printing instruction:

• taillight_plate - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.

• connector - 2 pcs, bronze/grey PLA, 100% infill, 0.15-0.2 layer.

• isolation_plate_top - 1 piece, brown PLA, 100% infill, 0.15-0.2 layer.

• isolation_plate_bottom - 1 piece, brown PLA, 100% infill, 0.15-0.2 layer.

• top_red_cover - 1 piece, clear red PLA, 100% infill, 0.15-0.2 layer.

• bottom_red_cover - 1 piece, clear red PLA, 100% infill, 0.15-0.2 layer.

• bottom_clear_cover - 1 piece, clear PLA, 100% infill, 0.15-0.2 layer.

• taillight_rubber - 1 piece, black PLA/TPU, 100% infill, 0.15-0.2 layer.

Glue together the top_red_cover,  bottom_red_cover and the  bottom_clear_cover.

Put together taillight_plate, isolation_plate_top, isolation_plate_bottom and 2 pieces of the connectors. Srew 2 piece of M1.2-3 screw

Screw taillight_rubber and the plate assembly to the body with 2 pcs of M1.4-5 screws from inner side of the body

Install the outer cover and fix it by 2 pcs of M1.4-4 screws.

in the end you can make the last accesories. You can print it or not. It depends only on you..

Printing instruction:

• PAV_logo - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.

• registration_plate - 1 piece, height 0-0.3 white PLA, height 0.3-0.6 black PLA, 100% infill, 0.15 layer.

• international_registration_plate - 1 piece,  height 0-0.4 white PLA, height 0.4-0.6 black PLA, 0.15-0.2 layer.

PAV_logo glue on the body on left side near taillight. see picture below. 

For the registration_plate you have to drill 2 holes diam. 2mm. For fixing use 2 pcs of M2-5 srews with nut from inner side.

The international_registration_plate place on the other side of the tail light. For fixing you have to drill 2 1.5mm holes. The plate fix by 2 pcs of M1.6-3 screws with nuts from inner side.

Bill of material:

• 2x screw M1.2-2 mm

• 6x screw M1.4-4 mm

• 2x screw M1.4-5 mm

• 6x screw M1.6-3 mm

• 2x screw M1.6-4 mm

• 2x screw M1.6-5 mm

• 2x screw M2-20 mm

• 4x screw M2.5-5 mm

• 1x threaded rod M3-40

• 10x nut M1.6mm

• 2x nut M2.5mm

• 2x nut M3mm

• 2x ball bearing 693 EZO

• 1x wire of diam 1mm, long 132mm

• 2x spring from pen

• superglue

OPTIONALLY:

• 2x screw M1.6-3

• 2x screw M2-5

• 2x nut M1.6

• 2x nut M2

AND THATS IT ALL! 

If you've made it this far in the build, you can congratulate yourself. You've built a cool motorcycle with a trailer PAV eventually also with a sidecar.
I hope you enjoyed the build and I'll look forward to seeing photos of your prints in the comments.

And what's next?
I'm currently preparing a kit for a DKW 300 motorcycle, nicknamed Blutbase (blister) for its a red tank. I'm currently printing and assembling a prototype, from which I'll then use the photos to write instructions.

For now, you can view photos of the build, which I'm regularly adding to the album. See here: https://www.rajce.idnes.cz/jawarmaniak/album/3d-tisk-dkw-300-luxus-blutbase

The motorcycle will be built to the same scale as the Jawa, so the size and laboriousness of the build will be similar.

The model is available here: