Building a sidecar the Harley-Davidson way

A brochure in the Harley-Davidson Museum™ reveals how H-D made sidecars at their Juneau Avenue factory in the 1920s

“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

The first Harley-Davidson® sidecar was produced 110 years ago in 1915. In the 1920s, the company published a brochure titled Building a Sidecar the Harley-Davidson Way. By highlighting the materials and construction process, it sought to educate riders about the quality of the H-D® sidecar – as well as its superiority over other models on the market.

A quote from the brochure’s intro says: “We ask you to compare this masterpiece of ease and art with the other makes on the market and let your own motoring desire be the judge. In the meantime, we hurry on in the building of your eventual choice.”

The black and white brochure focused on sidecar bodies and frames, forgoing wheels, tires, bearings, and the motorcycle itself: “The wide expanse of related industries reaches beyond the rider’s interest and our limit of narration for these few pages.” Check out some of the key production stages discussed in the brochure, with original photos and text. For more photos and discussion of the process, visit the Museum’s Google Arts & Culture exhibit.

Want to know more about the Harley-Davidson archives collection? Curious about a particular element of H-D history? Email enthusiast.int@harley-davidson.com for a chance for the archives to answer your questions in a special post for Ask an Archivist Day this autumn.

The rotary cutter in action. Each steel sheet is marked over a pattern and the expert operator follows the markings accurately and rapidly, making each part uniform in the thousands of Harley-Davidson sidecars
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
Spray painting gives the body coat after coat of the smooth, velvety, olive drab colour which has become so well known globally. The body undergoes the baking process between each coat of paint
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 but soft cushion structure
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
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

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