first smallie project, vespa 100

[henri]

Attachment DeletedAttachment Deletedi, new to this forum an smallies in general ,but have had a itch to own one for a while ,an being a "serial resto artist" on other scoots ,large frames an lammbretta's ,just had to complete the set by getting a smallframe to do aswell. an it doesnt hurt that i'm into customising/tuning/upgrading aswell when appropriate,an smallframes are well covered for in this area an forum.

am also liking this forum as it seems more open to other stuff ,like lardys (your name not mine) an classic cars an other projects ,an peoples individual choice's over original/upgraded/tuned ,no doubt i'll discover the different camps (mod/scooterboy/racer/originallity) an probably get slagged doing it,but i'm a big boy an ugly enuff not to care ,so no plees to "play nice" from me.

anyway am posting to ask for advice on smallie specific stuff ,like who's the best shops for parts,in particular a floor repair panel ,apart from sip ,as most of the ones ive found on-line are pictured minus the "k" re-inforcing plates ,an if kitted with a basic 135cc kit which exhaust is best/equivalent to say a sip road 2 pipe on a large frame ,for low torque increase over high bhp, a "touring" exhaust rather than a racing,if ya see what i mean,  an a rough guide to the carb mods needed to get the best out of a 135cc kitted scoot, IE<manifolds/carbs/air filters , an finally the scoot is only missing a number plate holder/bracket an a seat ,so any guidance on seat choice/style/size is appreciated ,thanks henri 

[gav]

Hello henri and welcome, we like big boys on here good luck with your project

[henri]

Attachment DeletedAttachment DeletedAttachment Deletedrogress so far ,back to bare metal an then rust-cure washed ,all surface rust sanded off ,cept for floor corner thats being replaced ,got a whole floor panel from disco dez for a tenner more than just the re-inforcing k patch from sip.welded the frilly bit at leggys/floor junction edge beading, ground an planished it back an hidden by 2 coats of filler primer,as is the minor pitting by brake pedal ,an frame in etch an primer now ready for the azzura laguna paint on the shelf .

stripped n checked engine ,seems the 7000 miles on clock is close to right ,as theres no measurable wear , will new bearings n seals which ive got an match cases to a dr130 kit i'm waiting on ,unported for a start an matched to a polini cheapn chearful pipe ,which cost 32 quid an turned up with a broke mount weld, so got a apology n 15quid refund an 20 mins on the welder ,which as its a polini i was expecting to fettle to fit anyway is no hardship, will start with a polini spring in clutch an maybe diff plates .

thinking of the carb ,i'm wanting to ditch the dellortto 16/16 but not for a 19/19 but maybe a keihin or prob a mikuni clone , an make up a carb-bellows less manifold , probably with car water hose instead .

an made up a new set of beading tools as smallies are 8mm round an all my large frame 1 's were 10mm. only things major i'm missing is  a friction free cable kit an a seat ,most of the new 1's ive seen arent that good quality/fit , any hints or tips . Henri

[Tiberius]

First thing to be checking is the clutch basket, are the turrets clean as I've lost count of the amount of motors I've seen built with buggered baskets although you don't strike me as someone who'd miss on that going on your previous posts. Probably as well changing the plates and steels in the clutch for all the cost of them really and Surflex are agreed as the best for a standardish motor.3 plate will be enough for your DR.

[henri]

on the edges of the basket theres ghosts of marks ,no burrs/ridges/blueing at all,so reckon its good to go again, scoot was owned new by a guy for 2 years an then a italian woman in london who kept it on the road til 96-98, the speedo' shows a tad over 7000 an theres mots to back it up .tho ya never know how long it cud of been run without a cable/broke speedo, but all signs inside an out are of that fabled "1 lady owner" type of scoot.on my large frames ive quite often used newfren corks an brake shoes ,there middle to cheap in price an do the job ,tho with clutches there never on long on a large as its a bit of a weak spot in the design. will check out surflex as ive seen em mentioned on here a few times.aswell as a polini spring.
whats the crack with going 4 gears ,is it just swapping the fixed n loose gears an selecter aswell i guess, an is it a pk box to look for donor parts ,or is there extra's to do, or can you play with the ratios on a 3 speed an get a better box for a dr kit .changing the primarys or different loose gears ,which an were from . thanks henri

[tzsteve]

a four speed box is just nicer in everyway you can mention and essential for 125/135
get a complete second hand box.

if you are going from 100 to 125/135 get some standard 125 primaries (not too expensive) if you have a bit of extra cash consider an alloy clutch and clutch basket, a tuned 125/135 may need slightly lower ratios
just options to look at

[tzsteve]

not had a lot of experiance with the pk stuff but the rear axle takes a different wheel to the old v range and i have a hunch the brake back plate may be different as well.

[henri]

Attachment DeletedAttachment DeletedAttachment Deletedore progress so far , first pic is the 1/4 floor panel repair going in ,2nd just a bit of filler to blend in a inch square welded in patch next to brake block ,an 3rd pic a smear of knifing putty to flat back over floor weld an then primered ready for flatting an top coat , got that an the seam sealer on an another coat of primer done an inside rear arch n mudguard in stone chip/enamel in a dark grey to match the blue/grey "azzura laguna " top coat ive got to top coat it with.i got a polini exhaust ,banana style for 20 quid as somebody had broke a weld on the mount trying to force it to fit ,welded up n painted with b&q barby paint ,matches the matt-black factory finish an lasts longer . just waiting for the dr 130 kit ive ordered to fettle it to fit ,

the other bits i was missing came with a second smallie project i bought at the weekend ,a fast-back seat with a piaggio cover ,stitching has rotted out on 1 seam but its a easy sewing job ,i'm dropping of a custom seat base n foam at the trimmers tommorrow an will pick up the right thread then . an i bought but forgot to pick up a pk internals set ,have to go back nxt saturday to get it , just a carb to choose an get an a new friction free cable set to order , anybody on here get any use for a new/old stock unused standard exhaust ,as i wont be using it . Henri 

[henri]

Attachment Deletedust got 2 coats of celly primer on an it starts thundering n then rain ,so flatting back n topcoat will have to wait , the spaniard in foreground got 2 thick coats on its "bottom" n front of leggys too, will take some rubbing back as there had been some "reaction" with the stone chip rob had painted in it ,crazy paving look isnt for me ,ignore the lardy on the floor ,its in for welding after i straightened the frame ,an a et4 steering column n zip motorcycle forks .the drapes are 99p store camping tarps an convert a filthy dusty garage into a "spray shop" in 20 mins ,rather than 2 days cleaning an emptying an also stop overspray going everywhere . for cars n on-site spraying i use them an the frame of a 18quid gazebo .
took another seat base to trimmers (£90+vat) an he had a look at the split seam in piaggio seat cover an machine sewed it up for a fiver while i waited ,bargain,much neater job than i cud do by hand .hopefully i'll get some of sunday morn in garage flatting back an topcoat nxt weekend .H

[tzsteve]

progress again

[Spanish Rob]

See you tomorrow

[henri]

Attachment DeletedAttachment Deletedote to self ,nxt time ya drunk an tryin out paint colours n coachlines on a bare frame ,usin old rattle cans on the shelf in garage ,dont use up all the etch primer unless your going to rub back to bare metal again . had lent the orbital sander to mate who's painting a vbb an sportique we own jointly ,so just blew over with 1 coat of etch an 1 of barrier (which was ancient an not covering well) ,an got a little reaction,just 2 cracks radiating from horizontal seam on horncast ,so rubbed back to bare for about 5" around both sides an couldnt be arsed to drive 10 miles on a sunday to get more etch ,thought i'd leave it til nxt weekend .sprayed the spanish frame with 3 coats of primer n flatted back an there was enuff paint left in gun to cover the bare metal to stop any surface rust so just blew it over ,knowing it would have to come back off for etch nxt time .an got a massive reaction with 6" diameter sheets of paint sloughing off ,horrible , 
so gave up on painting for the day ,an de-greased n steamcleaned my cases n headset n other bits , blew out any damp from corners/holes with brake/carb cleaner an gave a mist of wd40 to stop ali going flaky . new bearings n seals an a petrol bath next an build .prob be a couple of weeks as ive got the car to weld for a week from thursday an to match the cases to barrel before bearings . H

[henri]

had a few hours off from welding the missus's car an rubbed back to bare metal an got 2 coats of etch primer on an no reaction ,soon as cars done will get more primer on it an get on with top coat . also drilled the new floor section for floor runners ,so a little progress this weekend . H

[henri]

Attachment DeletedAttachment Deletedfinally got car welded an back together an can get back to scoots , on left is a brand new polini exhaust 99quid that somebody had ripped the mount welds trying to fit, i got it for 21quid an ten mins with dremel n stone is ready for a blob from the electric pigeon machine .on right is it 10 mins later welded whilst fitted to empty cases to stop distortion ,2 coats of b&q matt black barby paint an when dry is ready to hang in shed for when lump is built,had a look at top of downpipe an polini weld a ring inside the pipe to fix to flange pipe ,so i reckon too weld around the outside an blunt a "burr" grinding back the inside weld to get rid of constriction,an open it up a touch for better exhaust flow .
have been comparing the v100 cases to pk 50 1's an theres loads more scope to match to the barrel on the pk's an the 3 stud inlet manifold an inlet tract are so much better aswell. but theres damaged an broken studs all over an bearings were left in before an after vapour/steam cleaning an i dont know what further damage is there .prob build the v100 with the dr kit an also go a bit further with the pk's ,Henri

[smashingfish]

imgflip.com/i/b5jld

[henri]

thats prob what my teacher in the naval dockyard wud of said aswell ,i'm happy with it on a 30 year old welder an the fag end of a disposable bottle ,its full penetration an i aint botherin to pretty it up with grinding, so come on smashingfish post sum piccys of ya weldin an tell me were i went wrong , i'll need the tips nxt time i get "coded" , henri

[henri]

Attachment Deletedwas movin the v100 round today an noticed a crack around the outside edge of k reinforcing plate ,had a good look an it seems only to be attached by spot-welds along the inside edge behind the spine of the k, cant see how any spots would of rusted through without it showin on either side of the floor surfaces so guessin the guy doin job in factory had a bad day or was just a lazy bleeder , probably widen it an get a load of rust killer into the seam then just seam weld it down ,cant be arsed to cut it off an plug weld another reinforcing plate on ,was movin the scoot as i thought it was ready for painting underneath so annoyed, but better now than in a few weeks when its painted . H

[Mike Bennett]

Doing some good work on this. I've got a Spanish primmy 1974 and donno where to start- overwhelmed but optimistic but your one is comming along great.

[tzsteve]

thats scooter quality for you.
remember they were built at a throw away (last 5 years) price so quality control has always been minimal.

bash it together botch it up and get it out the factory gate

[henri]

sounds like me on a bad day , an this scoot was built prob 79 ,so probably a strike was called half way thru spotting it an guy couldnt be bothered to finish the job ,all over soft bog paper in crapper/choccy biccys at tea break/or a welder looked funny at a painter ,piaggio in 70's was worse than liverpool dockers ,always on strike/work to rule,
an harveymushman ,make a list of jobs to do an always cross 1 off every weekend ,even if its just changing a bulb, if ya keep progressing it keeps ya wanting too,a stalled project left too long usually ends up on e bay , an i aint got the money/space for another scoot just yet, the vulture has eaten an is digestin his last 2 scoots bought, H