Gilera Runner 500cc.
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Ossessionato
Vespa LX150 GTS250ie GTS300x2
Joined: 11 Dec 2009
Posts: 2014
Location: St. Pete, Fla
Mon May 06, 2019 2:18 am quote
Still a fascinating project!!
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Sat May 18, 2019 9:53 am quote
Made the side stand bracked to fit.
And welded it back on the frame.
Then made the brackets for the helmet box, and welded them on the frame.





Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Sat May 18, 2019 9:55 am quote
Started with building the first part of the left shock absorber mount.
This also connects the new frame tubes with the old rear section.
To fill that big gap, i welded 2 extra 6mm thick steel parts together.
Alligned everything and spot welded them.
Next time i wil make the new right side shock absorber mount, and compete the welds.
Then i can make the second part of the shock absorber mount.






Hard to see, but made ga gap with the grinder.
And bended the part in a angle.
And then welded the gap again.













Addicted
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 737
Location: Toronto
Sat May 18, 2019 2:24 pm quote
Keep it up!
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Jun 06, 2019 10:49 pm quote
Started with the inner brackets for the shock absorbers.



Making the helmet cover fit again.
This is in a rough way, will close it the right way later on.
Put back the fairings, and everything fits nicely.
The rear shockabsorbers have plenty of room, no need to modify the fairings for that.





Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Jun 06, 2019 10:55 pm quote
Resumed with the shock absorber mounts.
Below these mounts i welded big M18 threaded studs.
I will make 2 tools for that.
One that i can mount on them to transport the bike.
And one when i need to adjust the head valves.
This is to remove the engine easy, the frame will have his own support then.
Because to adjust the head valves, the engine needs to be removed.
The engine has the center stand, and will be supported by that.







Rear side is ready.
And the side stand is ready.



Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Jun 06, 2019 11:09 pm quote
Installed all the covers to check if it all fits correctly.
It all fits like a glove









Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Tue Jun 25, 2019 12:56 am quote
Installed the original front fork with the original wheel.
And the spare Fuoco 500 engine.
With the to big Beverly Cruiser rear tire.
Did this to test how the scooter behaves.
Went down a small hill, and the bike behaves perfect.



Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Tue Jun 25, 2019 1:00 am quote
Did some recycling today.
Used some old frame parts to make some brackets.
These are to move the radiator cover a bit more to the front.
Because the new radiator is thicker.







Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Tue Jun 25, 2019 1:13 am quote
Put all the covers back on.
Took the front out of the belt cover.
By this way i can easy mark the left engine cover where the plastic needs to be removed.
The rear wheel is getting a powder coat at this moment.
And the correct rear tire is ordered.



Addicted
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 737
Location: Toronto
Tue Jun 25, 2019 1:39 am quote
This is really coming along! Thanks for sharing the process and pictures!
Hooked
'13 Buddy 125 Seafoam
Joined: 25 Oct 2018
Posts: 212
Location: Southcoast, MA
Tue Jun 25, 2019 5:59 am quote
subscribed...love this stuff...this bike is going to fly...great to see someone with talent build exactly what they want and make it look good...you should see the hack job project scooters in my area
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Jun 27, 2019 10:23 pm quote
Modified a rear wheel adapter. (Just for testing)
One bearing fitted directly, the other one i had to place with 2 component epoxy.
The front tyre a Michelin Citygrip 110-70 13S is installed on a 13 inch rear 1800cc wheel.
Checked how it looks with the original front fork.
A 13 inch front wheel actualy looks pretty good, and the front fender wil fit correct.










Made the transport brackets at the front and rear.
The rear bracket is also to remove and install the engine when the valves need to be adjusted.

Modified the left engine cover, and installed the belt cover.



Hooked
300 super sport Full Malossi and carbon Edition
Joined: 26 Nov 2016
Posts: 112
Location: Netherlands
Fri Jun 28, 2019 9:49 am quote
Tjonge tjonge wat een gaaf project,respect man
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Fri Jun 28, 2019 12:08 pm quote
335Rick wrote:
Tjonge tjonge wat een gaaf project,respect man
Ach, het houdt je van de straat
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Fri Jul 05, 2019 1:39 am quote
The rear Nexus wheel is back from the powder coater.
And the Michelin citygrip 140-60/ 14 S is installed.



The difference in height, left is 60 and right is 70.
60 looks mutch better.



Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Fri Jul 05, 2019 1:41 am quote
The standard brake master cilinder of the Runner is 13mm.
That is to small to operate the 2 Brembo front brakes.
So ordered a 16mm master cilinder from Brembo.
Had to modify the steering hood, and the front spoiler wil cover that.
Also the Runner gets a dual throttle cable gas lever.





Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Fri Jul 05, 2019 1:44 am quote
Installed all the covers.
And the Beverly 500 front fork with the 13 inch front wheel.
The front fork has to go up a little bit.
The overall the look is perfect with these wheel sizes.

















Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Mon Jul 08, 2019 10:40 pm quote
All the covers are off the bike.
And the transport brackets mounted.
Its now to a specialized company who will make the custom alloy radiator, inlet manifold and cooling pipes.



Veni, Vidi, Posti
74 50s x3 78 P200 84 Cosa 58 AllState 68 Sprint 80 50special + projects
Joined: 22 Nov 2010
Posts: 7331
Location: seattle/athens
Mon Jul 08, 2019 11:43 pm quote
You pulled it off nicely.
Paint that front wheel to match the rear and it looks factory, nobody would guess what lurks under the pretty plastic.

And what a monster patiently waits...
Molto Verboso
2018 GTS300 Super Sport - Donatello Vespace
Joined: 22 Dec 2012
Posts: 1290
Location: Toronto, Ontario Canada
Tue Jul 09, 2019 5:03 am quote
Very cool project. Thank you.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Jul 11, 2019 1:27 am quote
V oodoo wrote:
You pulled it off nicely.
Paint that front wheel to match the rear and it looks factory, nobody would guess what lurks under the pretty plastic.

And what a monster patiently waits...
The new front wheel with dual disk brakes will be the same grey as the rear wheel.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Wed Jul 17, 2019 2:36 am quote










Member
Joined: 17 Jul 2019
Posts: 9
Location: Santa Clara, CA
Wed Jul 17, 2019 8:56 pm quote
Impressive Project.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Tue Jul 30, 2019 10:32 pm quote
Made the brackets/tools to install and remove the engine easy.





The last job for the frame is to use it as a fixed point to make a small bracked where i can install the righthand mirror on.

First installed the original master brake cilinder, and made the fixed point bracked.
Then installed the 16mm master brake cilinder, and made the small bracked.
Now i can mount the righthand mirror on that.











Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Sun Aug 04, 2019 11:04 pm quote
Installing and removing the engine is verry easy with the dolly.
And test fitted the Bitubo rear shocks.
(Installed a old fuel tank, to cut open for test fitting)







Test fitted the unfinished crosflow radiator.
Verry tight, but it will fit.
Also test fitted the unfinished waterpump, have to modify the plastic cover a little.





Addicted
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 737
Location: Toronto
Mon Aug 05, 2019 3:54 am quote
Looking great!

How close would you say you are to completing the project?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Mon Aug 05, 2019 4:26 am quote
End off this year i want it technicaly ready.
And next summer complete ready with the new covers.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Wed Aug 21, 2019 4:36 am quote
Some pictures of the progress of the front wheel.







Addicted
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 737
Location: Toronto
Wed Aug 21, 2019 9:29 am quote
This is beautiful madness!
Hooked
2010 gts 300 super. 09 MP3 500 lite
Joined: 02 Apr 2013
Posts: 442
Location: tampa
Sat Aug 24, 2019 2:48 pm quote
OMG! who are you? this is some serious madness.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Aug 29, 2019 8:27 am quote
The front wheel is almost ready.
Needs to go back one more time for some modifications.









Hooked
2010 gts 300 super. 09 MP3 500 lite
Joined: 02 Apr 2013
Posts: 442
Location: tampa
Thu Aug 29, 2019 11:13 am quote
was making front wheel lighter a goal here? are you planning a matching rear?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Aug 29, 2019 11:16 am quote
No, there is no dual disk front wheel in 13 inch.
So it has to be made in the Runner model.
Rear wil also be this model, and in 14 inch.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Sat Aug 31, 2019 10:52 am quote
Started with the welding of the HD-PE fuel tank.
When the welds are complete i will melt in stainless steel mats.
This is to make the welds extra strong.
And then put over the mats some extra HD-PE.
I measured with water how mutch the tank can hold now, and that is 8.25L.
I can make the tank at the front bigger, at the place where the voltage regulator and fuses were.
After that i will have around 9.5L fuel onboard.









Hooked
Zip50 hyperscooter 188cc
Joined: 27 Feb 2012
Posts: 151
Location: Athens,Greece
Sun Sep 01, 2019 11:59 pm quote
This is the King of scooter projects.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Thu Oct 03, 2019 10:31 am quote
The fuel pump bracked is back from zinc elektroplating.
The crossflow radiator is finished.
And the new twinspark cilinder head is modified.











Enthusiast
Aprilia Scarabeo 500
Joined: 02 Oct 2019
Posts: 69
Location: Florida
Fri Oct 04, 2019 11:50 am quote
Dang, one of the coolest scooter projects I've ever seen. Will definitely be following this until completion.

Are you planning any sort of modifications for the motor? Clutch? Sliders? etc...?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 76
Location: Netherlands
Sat Oct 12, 2019 10:53 am quote
Scarabeo500ie wrote:
Dang, one of the coolest scooter projects I've ever seen. Will definitely be following this until completion.

Are you planning any sort of modifications for the motor? Clutch? Sliders? etc...?
Will be adjusted on a power bank.
And probably Dr pulley sliders and a Dr pulley hit clutch.
Enthusiast
Aprilia Scarabeo 500
Joined: 02 Oct 2019
Posts: 69
Location: Florida
Mon Oct 14, 2019 11:23 am quote
Arnoh wrote:
Scarabeo500ie wrote:
Dang, one of the coolest scooter projects I've ever seen. Will definitely be following this until completion.

Are you planning any sort of modifications for the motor? Clutch? Sliders? etc...?
Will be adjusted on a power bank.
And probably Dr pulley sliders and a Dr pulley hit clutch.
I am certainly curious on your choice of tuning software and how it works. Also interested in a review regarding the HIT clutch.
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