THE FRAME

plan

1. build an adjustable jig to hold the frame in correct alignment. As the channel has been cut out, the heat from the welding will pull the frame this way and that.
   

is this the zen then?

One of the hardest things when fixing up (or getting ready to prepare for the pre-fixing up preparations) a fucked up old scooter is hearing about the complete one that just got sold a month ago for the price you are going to end up paying for the bloody headset. I am on the verge of becoming even more determined to fix up the unfixable, no matter what the cost is to my sanity, wallet and marriage.
I must get this frame started before something comes up. Hours spent working on the steel are free (well, no dearer than hours on the computer looking at ebay, scooterbbs, yahoo groups scomo, sip, scooterworks, beedspeed, scootrs, australian scooter parts, gps imports, worb5, etc, etc.)
the next post will be my plan/ progress on frame strengthening. I will return to this and update as I go.

another day

Today my floor arrived, along with my repro tail-light, tank rubber , hand grips and "sexy asian girl with scooters" calendar.
My spirits are uplifted after the headset disappointment, as now I can start working on the frame re-inforcing.
There is one hope on the headset front, and that is if the buyer messes about and the sale falls through. Fingers crossed as the seller seems to have much of what I need, and a good relationship with him will be of great benefit in the long run. Making knowledgable contacts in distant lands is not just handy, but is part of the fun of scootering.

On the frame front, I have all but decided to do the following:

• cut out and remove spot welds on old floor
  
• make steel jig to hold frame dead straight and in the correct position (as the centre channel has been compromised, the frame can easily twist until the floor is back in)
  
• weld structural support inside frame channel
• weld large pipe inside channel for cables and wiring
• tack on plate to front section of channel ( been cut out by previous owner)
• tack on new floor
• repair rust holes in side cowls (not overly concerned as they are not structural).
  
• take the frame to a panelbeater for a full weld up
• get the panelbeater to smooth out legshield, cowls and ding near seat.
• get the panelbeater to treat and prime frame.
• spray it myself. The main reasons for spraying myself are..1) cheaper 2) I would rather have a straight looking old scooter than a bright shiny, half arsed restore job.. 3) I will probably mess up the paintwork while trying to fit motor/ cables/ tank etc. as I have no experience whatso-ever in this field.
  

first ebay upset

just woke up and checked my ebay bid for a complete headset. The auction finished in the middle of the night and I was outbid. Now we get to find out how rare the split headsets are.
I'm hoping they are unwanted and unloved in the collector community. I bid up to 40 pounds (90 australian) and there was one other bidder (40.50).
Oh well, move on.

what I need..

1. engine. p200. prefer elec start. (I'll deal with the engine bits in another blog - perhaps www.dirtyrocketengine.blogspot.com )
2. headset (prefer complete with handlebars) vna/vnb split headset version preferred as it is the one that was originally on the bike. using a split headset was used on this model only before going back to the one piece, eventually returning to the idea in the late 70's with the P series. I am guessing the advent of indicators and elec start meant more wiring, and therefore the return of the split headset made wiring easier. As I am planning on using p-series wiring, I think sticking closely to the unusual (and original) headset will suit the 'p' conversion quite well. (all guesswork of course).
3. forks. ..... from my research on the various chat rooms, etc I think the PK 125 fork will be the best bet. Others say rally ones are better, but as far as I can tell they handle like dogs and don't allow performance shocks like sebacs, or bitubo. Also I will add a disc brake conversion to this when there are funds available. ( I believe around 400 aud ).
4. New floor from scootrs in vietnam. Already ordered.. just hope I got the right one.
   
5. cables........ must find out if i need p200 ones, or original ones
6. wheels and tyres (maybe even the new tubeless ones from australian scooterparts)
7. long seat .. I have a single seat from scootrs, but I am not comfortable on those because of my size (5'11" 105 kg)
   
8. floor rails
9. head bearings... I think i need both sets (pk and vna) but it is something I'll have to check
10. fuel line
11. speedo ( assuming the headset I get doesn't come with one)
12. wiring loom .. I am assuming that I need a p200 one
13. possibly a px tank with oil tank (If I go with a autolube carb suck as a vortex)
14. rear light
15. side cowl fixings. The engine cover one clips on, and the left one bolts on permanently.
16. paint.. interesting decision, but I like the idea of a matt colour in an extremely dark green. Either that or white. Matt-finish helps with covering up bumpy panel work. We will have to see what can be achieved with the panels.
17. seat hingesm and catches
18. cowl rubber
19. rear brake pedal, cable.
20. ...etc etc
    

what I'm starting with...

FRAME:
bare frame. ....Before losing heart (and buying a harley style honda) the previous owner had the frame media blasted and has cut the centre channel of the floor out right up to the bottom of the horncast.

side cowls. ... both are stripped bare. Both have rusted through in pinholes around the bottom. The toolbox side is straight and the engine side needs beating ( in a do-able spot).

28mm round slide japanese carby (Keihin) - not sure if I'll use it, but I have it.

PX200 head (USA low compression) (probably won't need this either)

one of the stupidest projects ever

I'll start with a disclaimer.
At this stage I don't know what I'm doing.
By the end of this I will.
This project is not about ending up with a restored vintage vespa.
This project is a combination of the following....
The desire to have my favorite kind of scooter. ie. old and ratty.
The desire to have a reliable, tuned p200 motor concealed in a vintage body.
A need to learn to work on a long term project, forced to be patient by the unavoidable wait for parts. Now that Mr. Miyage is dead, we are all on our own when trying to learn patience...
'overpriced parts on....... rust off'
So, here's the plan.
I have a basket case 57 vna vespa frame, which would be considered beyond hope by vintage collectors/ restorers. I, however, have a metal working factory and plan on repairing the rusted frame in a manner that will make it stronger than original. The main reason for this is that the frame was originally designed to have a pissweak 125 motor, and 8"wheels. I plan on higher speeds, higher loads and more efficient braking, each of which will put a rust damaged 50 year old frame under too much pressure.
Time for some pics. Next post will be the bits I have, and the bits I need.
(you may work out soon that I am using this blog as a way of remembering stuff).
derek