Gilera Runner 500cc.
Post Reply    Forum -> Project Reports Previous123
Author Message
Hooked
2016 MP3 500 Sport
Joined: 21 Jun 2007
Posts: 112
Location: Indianapolis, Indiana
Sat Oct 26, 2019 5:55 am quote
Your engineering genius, passion and great skills have demonstrated that what can be imagined is possible. Congratulations on a beautiful build!

Marty
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 74
Location: Netherlands
Fri Nov 01, 2019 1:13 am quote
Finally had some time to resume with the 500cc Runner.
Resumed with making the fuel tank bigger at the front.
Filled the tank with water, and it holds 8.8 litres now.
Thats more then enough for me.
The original tank (old type) holds around 8.5 litres, so its a small improvement.
And its not my daily driver, just for fun.

Made the places where the welds are extra strong by melting in stainless steel mats.
And over these mats i melt some extra HD-PE.











Hooked
2010 gts 300 super. 09 MP3 500 lite
Joined: 02 Apr 2013
Posts: 441
Location: tampa
Fri Nov 01, 2019 6:04 am quote
fascinated with custom gas tank. is the screen used with epoxy for reinforcement? welding plastic not strong enough by itself?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 74
Location: Netherlands
Fri Nov 01, 2019 6:09 am quote
jerryd wrote:
fascinated with custom gas tank. is the screen used with epoxy for reinforcement? welding plastic not strong enough by itself?
The stainless mats are just melted in the PE-HD, no epoxy.
The welds should be strong enough, but i make it extra strong.
The tank is just a few centimeters away from the engine and hot exhaust.
What if it will leak, then the chance of a fire is big.
Therefore better safe then sorry.
Hooked
2010 gts 300 super. 09 MP3 500 lite
Joined: 02 Apr 2013
Posts: 441
Location: tampa
Fri Nov 01, 2019 6:15 am quote
can you post a picture of the welding gun? or are you just using standard heat gun?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 74
Location: Netherlands
Fri Nov 01, 2019 6:24 am quote
jerryd wrote:
can you post a picture of the welding gun? or are you just using standard heat gun?
This is to melt the stainless mats in the PE-HD

https://www.az-reptec.de/de/schweissgeraete/Schweisskolben/schweisskolben-sk60-0-220-v-60w-stufenlos-regelbar.html

And this to weld the PE-HD fuel tank.

https://www.az-reptec.de/de/schweissgeraete/heissluftgeblaese/heissluftgeraet-steinel-hg-2520-e-im-koffer.html

They also sell the PE-HD plates and welding rods.
I also baught ABS plates and rods there for the modification of other parts.
Enthusiast
Aprilia Scarabeo 500
Joined: 02 Oct 2019
Posts: 68
Location: Florida
Wed Nov 06, 2019 9:59 am quote
Simply amazed at the attention to detail on this. A lot of hard work going into this and can't wait to see the final product.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 74
Location: Netherlands
Thu Nov 14, 2019 11:14 pm quote
Made a bracket to mount the fuel tank at the rear.
And found a good location for the fuel filter.
This cant be mounted inside the fuel tank anymore.

Also made the bracket at the front.
The fuel tank is finally ready now.








And modified the radiator cover.
The Beverly 500 front fork is wider than the original front fork.
To make it fit, i need to make the radiator cover wider.

First i made 2 brackets to hold the mounting points for the side covers in place.
Then i made a curved metal plate to shape the plastic from the radiator cover.
I placed a teflon sheet between the curved metal plate and the plastic radiator cover to prevent scratches on the plastic.
Then i heated the plastic radiator cover to 350 degrees celcius and reshaped it so the wider Beverly 500 front fork fits.
Tested it first on the old radiator cover, and then modified the new radiator cover.











Team Scooter Trash for Petfinder Foundation   Vespa Wasp Pin Badges   Scooter Parts Company
Post Reply    Forum -> Project Reports Previous123
[ Time: 0.1163s ][ Queries: 23 (0.0251s) ][ Debug on ]