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Post by yatesy88 on Jul 28, 2014 3:10:43 GMT
Hi there. I thought it would be good to post about my project. I have been observing some threads and had to come on here often to find some tips and tricks, otherwise there would be no way in hell I would be able to rebuild my scooter. The project is stalling a little at moment due to lack of funds but It is a good opportunity to post Well a couple of months ago I purchased my first ever scoot with some gentle persuasion from my flatmate who has Lambretta's and Vespa's. It is a 1968 Vespa SS90, engine number *5132*. It's a NZ new model without the dummy tank and spare wheel. I bought it off an older guy without personally viewing it which turned out to be a bit of a stupid move. On arrival after a test drive, I had the engine removed and case opened. Bad news... The thing was poked! Absolutely everything needed some love and attention. So I had no choice but to start chipping away. I bought a couple of guidebooks and spent countless hours researching online about rebuilding. While I was slowly purchasing things for the engine I figured the frame needed some love and on closer inspection found the entire body had some filler/bog on it in some way or another. The frame has now been soda blasted back to bare metal and I picked up the original front mudguard today from the panelbeater who did an amazing hammer and file job on it. I am currently shopping round panel beaters for a quote on hammer and file jobs for the rest of the frame. (no panel beaters in my friends or family) Anyway, ill start putting some before and during pics up. Please if there is anything that sticks out like dogs balls that Ive done incorrectly please let me know. This is my first mechanical rebuild and restoration so any advice is greatly appreciated. Attachment DeletedAttachment DeletedAttachment Deleted
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Post by yatesy88 on Jul 28, 2014 5:07:35 GMT
Some before and after stripping photos. Had to scrape off a lot of bog.
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Post by yatesy88 on Jul 28, 2014 5:17:49 GMT
More frame...
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Post by yatesy88 on Jul 28, 2014 5:22:31 GMT
Headset and front guard
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Post by yatesy88 on Jul 28, 2014 5:24:41 GMT
Front guard back from the panel beater today. Hammer and file work, zero filler.
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Post by yatesy88 on Jul 28, 2014 5:41:20 GMT
With the engine I've gone with the Malossi 136 with reed valve and PHBL 25 carb. I've added a Mazz full circle crank. Gearing is 29/68 2.34 straight toothed with a new 4 plate cork clutch. I've replaced the rear axle as the tip was worn along with all bearings and seals. The gear selector was also worn and needed replacing. With some time in the shed I finally got it back together.
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Post by yatesy88 on Jul 28, 2014 5:55:43 GMT
Clutch and primary gear
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Post by yatesy88 on Jul 28, 2014 5:57:18 GMT
Malossi kit
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Post by yatesy88 on Jul 28, 2014 6:00:14 GMT
.
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Post by yatesy88 on Jul 28, 2014 6:01:09 GMT
Some of the old gear...
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Post by yatesy88 on Jul 28, 2014 6:07:04 GMT
Does anybody out there have any idea how the leads coming off the stator plate go through the two holes in the crankcase. I'm changing to the 12v ignition with the Serie pro kit from sip and the leads are way bigger than the holes. Any help would be awesome!!
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Post by yatesy88 on Jul 29, 2014 1:51:25 GMT
Fresh back from the metal polishers.
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Post by henri on Jul 29, 2014 8:40:17 GMT
that is some top grade beating/filing on the mudguard, very skilled pro job, seriously nice , a word of caution on the original exhaust tho, as they rot out from inside from exhaust gases forming sulphuric acid you'll need as good a welder as the panel guy to get it looking good , i'm a welder myself an only weld exhausts when there un-replaceable or as a stop-gap to keep bike/scoot running til replacement arrives.where its holed is a bit of a stress area (downpipe to box joint) an quite often if not heat treated/annealed the stiff weld causes the flexible sheet metal to crack away ,normally down the edge of weld in use.at least it isnt chromed ,as you have to grind it right back or it encourages cracking by weakening the weld . an i hope your going to blow some laquer over the bits that are polished ,as you wont believe how fast ali can go back to being dusty/scabby, you can almost see it happening . have you sussed out what your doing with the broken headset yet, did you get the broken-off bits with the scoot as that will make repairs a lot easyier , if not you might have to hunt a while to get a decent replacement ,or use a primervera 1 for a bit, engines lookin good an should be fun to ride with . H
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Post by nick121170 on Jul 29, 2014 9:56:30 GMT
Looking great,did you use the Ss cases for the malossi?i don't think I could bring myself to do that but fair play your scoot,lucky bugger. Metal work ,well that's an art form eh?cracking job
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Post by nick121170 on Jul 29, 2014 9:59:03 GMT
With the leads that don't go through the casing holes,can you strip back the insulation and use something like heat shrink wrap.if Ss cases I personally wouldn't want to drill the holes out larger,imo
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Post by Spanish Rob on Jul 29, 2014 10:38:06 GMT
Looking nice. Small frame porn at its best! Did you check in with the register of frame numbers to see where it lays in terms of the overall frame production run? Does it have the lugs for the centre glove box and is that going to be a feature of your finished machine? Do you have the 70mph speedo or were the NZ models in kph?
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Post by yatesy88 on Jul 29, 2014 11:02:01 GMT
Looking nice. Small frame porn at its best! Did you check in with the register of frame numbers to see where it lays in terms of the overall frame production run? Does it have the lugs for the centre glove box and is that going to be a feature of your finished machine? Do you have the 70mph speedo or were the NZ models in kph? Spanish Rob, Thanks. Good to know I'm doing the thing justice. Unfortunately doesn't have a frame number as it's a NZ one (or from what I can see anyway) seems to be the common thing with these. No lugs but yes they will be a feature of the finished project. 70mph speedo on it, it was mph in NZ then.
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Post by yatesy88 on Jul 29, 2014 11:05:28 GMT
that is some top grade beating/filing on the mudguard, very skilled pro job, seriously nice , a word of caution on the original exhaust tho, as they rot out from inside from exhaust gases forming sulphuric acid you'll need as good a welder as the panel guy to get it looking good , i'm a welder myself an only weld exhausts when there un-replaceable or as a stop-gap to keep bike/scoot running til replacement arrives.where its holed is a bit of a stress area (downpipe to box joint) an quite often if not heat treated/annealed the stiff weld causes the flexible sheet metal to crack away ,normally down the edge of weld in use.at least it isnt chromed ,as you have to grind it right back or it encourages cracking by weakening the weld . an i hope your going to blow some laquer over the bits that are polished ,as you wont believe how fast ali can go back to being dusty/scabby, you can almost see it happening . have you sussed out what your doing with the broken headset yet, did you get the broken-off bits with the scoot as that will make repairs a lot easyier , if not you might have to hunt a while to get a decent replacement ,or use a primervera 1 for a bit, engines lookin good an should be fun to ride with . H Hi Henri, Thanks for the tips on the exhaust. So you think it could be repaired by someone skilled enough? Yea I was talking to the metal polisher about that and he said the same. Any products you recommend going in them? No broken bits came with the headset, all the broken bits were very sneakily covered up in bog. Today I've been given a guy to call who apparently should be able to fix the headset. So fingers crossed.
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Post by yatesy88 on Jul 29, 2014 11:08:26 GMT
Looking great,did you use the Ss cases for the malossi?i don't think I could bring myself to do that but fair play your scoot,lucky bugger. Metal work ,well that's an art form eh?cracking job Thanks Nick, yes I used the original SS case. Strictly bolt on only. Didn't want to destroy anything in case some one wants to revert to original later down the track. yep the guy is pretty talented, looking forward to what he can do with the frame. yea I managed to use smaller wrapping on the leads and they are through the original holes, no widening needed.
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Post by giramassi on Jul 29, 2014 13:09:18 GMT
Looking nice. Small frame porn at its best! Did you check in with the register of frame numbers to see where it lays in terms of the overall frame production run? Does it have the lugs for the centre glove box and is that going to be a feature of your finished machine? Do you have the 70mph speedo or were the NZ models in kph? Spanish Rob, Thanks. Good to know I'm doing the thing justice. Unfortunately doesn't have a frame number as it's a NZ one (or from what I can see anyway) seems to be the common thing with these. No lugs but yes they will be a feature of the finished project. 70mph speedo on it, it was mph in NZ then. That is not exactly true, my NZ 90SS has frame numbers albeit different from the Euro models as they were stamped in NZ, mine has 4 numbers above the motor panel door frame. Nice photos but I could not bring myself to changing a 90SS engine as it is perfect the way it is as god intended, luckily mine only needed new oil seals and giving it new piston rings just as a gesture. keep the photos coming as it is inspiring for my build.
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