First Scooter, not my first project. (Now going electric!)
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P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Thu Feb 04, 2021 8:45 pm quote
swiss1939 wrote:
Sucks you had to damage brand new paint, but you will appreciate the ease of use in the long run. Curious how it's being mounted in that opening?

Hate to suggest it but since you are still in disassembled mode, what about stripping and repainting the glove box?
It has tabs that squeeze through then make a snug fit. This is the primary reason I messed up the paint. Make the hole to fit, and it isn't big enough. Then you have to guess trim it to get the tabs to fit. That is when I skipped the Dremel, and caused the paint damage.

Current plan is to use a brush to touch it up. If that is just too ugly, I will repaint as a last resort.
Addicted
GL, PK, PE200 with hack, Sears Rust Badge
Joined: 24 Apr 2012
Posts: 956
Location: Deep in the heart of Texas
Thu Feb 04, 2021 8:56 pm quote
JimVonBaden wrote:
It has tabs that squeeze through then make a snug fit. This is the primary reason I messed up the paint. Make the hole to fit, and it isn't big enough. Then you have to guess trim it to get the tabs to fit. That is when I skipped the Dremel, and caused the paint damage.

Current plan is to use a brush to touch it up. If that is just too ugly, I will repaint as a last resort.
...Or you can buy this thing, cut a hole in it to view the gauge and call it a day.
https://www.ebay.com/itm/New-Vespa-T5-Px-Front-Leg-Shield-Tool-Box-Top-Tray/313304272467?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3Ddb511dd1d22645eda3c0f67eec00cfac%26pid%3D100675%26rk%3D7%26rkt%3D15%26mehot%3Dnone%26sd%3D353197767164%26itm%3D313304272467%26pmt%3D1%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3Ac48c7e8f-676d-11eb-add7-cabb723e3d24%7Cparentrq%3A70879a881770ad3550f02604fff0d642%7Ciid%3A1

You're doing some Great Work!
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Fri Feb 05, 2021 4:56 am quote
rowdyc wrote:
JimVonBaden wrote:
It has tabs that squeeze through then make a snug fit. This is the primary reason I messed up the paint. Make the hole to fit, and it isn't big enough. Then you have to guess trim it to get the tabs to fit. That is when I skipped the Dremel, and caused the paint damage.

Current plan is to use a brush to touch it up. If that is just too ugly, I will repaint as a last resort.
...Or you can buy this thing, cut a hole in it to view the gauge and call it a day.
https://www.ebay.com/itm/New-Vespa-T5-Px-Front-Leg-Shield-Tool-Box-Top-Tray/313304272467?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3Ddb511dd1d22645eda3c0f67eec00cfac%26pid%3D100675%26rk%3D7%26rkt%3D15%26mehot%3Dnone%26sd%3D353197767164%26itm%3D313304272467%26pmt%3D1%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3Ac48c7e8f-676d-11eb-add7-cabb723e3d24%7Cparentrq%3A70879a881770ad3550f02604fff0d642%7Ciid%3A1

You're doing some Great Work!
I like that. Not going to use it like you suggest, because I already mounted the gauge, but it is a great way to securely mount my fuse box. Plus I wanted a tray in there.
Molto Verboso
Vespa
Joined: 19 Jun 2007
Posts: 1261
Location: California
Fri Feb 05, 2021 6:18 pm quote
nice paint work my vote is for the block font same as the original on the leggy.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Sun Feb 07, 2021 7:40 am quote
Got some of the bike wiring done, and mounted some of the electric conversion components. This is a lot of wiring when you are 100% rewiring the whole bike!.








Wiring station:


Fuse box and LED flasher wired in. Plus a several harnesses done, and one main one to go:




Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Sun Feb 07, 2021 8:17 pm quote
Received my 4 AWG wire and connectors, so I could start wiring in the controller and associate parts.



Making the high power cables:







Installed on the controller, contactor and shunt:





Then wrapped and fed the bike wires through the frame, and connected the disconnect.










Next I need to start making all the connections. This is the fun part where I get to power up and test the circuits.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Mon Feb 08, 2021 7:27 pm quote
Doesn't look like much, but represents almost 4 hours of work. Don't worry, the bundles will all get braided covers, not just tape.




Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Tue Feb 09, 2021 7:51 pm quote
The engine electrics are done. Took a lot of time, but I am happy with the results. I also finished and covered the main harnesses towards the front, and battery area. Just need to do the tail light harness, and rear signals.






Obviously I have the motor hooked up for mocking purposes only. Until I mount the forks, front wheel and centerstand I can't install the motor.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Wed Feb 10, 2021 7:57 pm quote
Not much done. A fresh coat of paint on the "forks", and placement of the fuse block panel. Plus a shot of the rear wiring upright. Once the fork is installed I can install the headset and wire it up.








bodgemaster
63 GL, 76 Super (x 2), 74 Primavera (x 2), 06 Fly 150
Joined: 26 Sep 2013
Posts: 5653
Location: So Cal
Wed Feb 10, 2021 8:39 pm quote
Looks great Jim. Not to be nit picky, and to each their own, but I think a black suspension might give it a more modern look.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Wed Feb 10, 2021 8:51 pm quote
SoCalGuy wrote:
Looks great Jim. Not to be nit picky, and to each their own, but I think a black suspension might give it a more modern look.
You may be right. It will all need to come apart after I get it going anyhow. I am going to replace everything, and likely update it to a disc in front.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Thu Feb 11, 2021 7:17 pm quote
Some have asked for these.



Swingarm dimensions:









Updated Wiring diagrams.



Hooked
1963 Vespa VBB, 1965 Allstate Cruisaire, 1974 Vespa Super, 2003 Stella 2T
Joined: 31 Jan 2016
Posts: 125
Location: Kansas City
Sun Feb 14, 2021 9:26 am quote
Jim, I was wondering when you register this scoot what will you say it is? Electric? What Power? Would it be freeway legal? Does an electric scooter require a motorcycle endorsement to ride?

Loved every post of this project.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Sun Feb 14, 2021 4:25 pm quote
Chatis wrote:
Jim, I was wondering when you register this scoot what will you say it is? Electric? What Power? Would it be freeway legal? Does an electric scooter require a motorcycle endorsement to ride?

Loved every post of this project.
It is already registered as a motorcycle. Fortunately it is considered an antique, so no need to have it inspected. IF it were not, I would register it as an electric scooter, which does not require licensing in VA. While it may technically be classified as a 50cc or more (motorcycle), it would never get the blink of an eye since it is electric.

Lots to come, maybe tonight, maybe tomorrow. Valentine's Day and all that.
Ossessionato
62 VBB1T Round Tail W/ leaner sidecar
Joined: 26 Jan 2019
Posts: 2036
Location: california
Sun Feb 14, 2021 11:04 pm quote
looking forward to the next update.
Much appreciate the updated wiring diagram - and pics of layout.
Like the crystalizing of updated version of Resistors build - tho quite similar in basic lay out - seems you will get a bit more top speed.
Good road map - interested to see results.

So - what's next?
How long 'til the video showing cruising speeds?
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Mon Feb 15, 2021 6:44 am quote
charlieman22 wrote:
looking forward to the next update.
Much appreciate the updated wiring diagram - and pics of layout.
Like the crystalizing of updated version of Resistors build - tho quite similar in basic lay out - seems you will get a bit more top speed.
Good road map - interested to see results.

So - what's next?
How long 'til the video showing cruising speeds?
I'm confident Resistor's is likely better done. But, I hope to have a test ride by next weekend.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Mon Feb 15, 2021 6:50 am quote
First, installed the front tire, all new:



Then installed the fender, removing and reinstalling the fork.



Installed the rear hub and brake lines:



Cleaned up all the wiring, ready to test all the connections:




Then installed all the lights and test fit the bodywork:









I'm happy to say the lighting system works perfectly, and the body fits nicely!
Molto Verboso
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 1232
Location: Toronto
Mon Feb 15, 2021 7:49 am quote
Looks clean!

Those look like filament bulbs? I'm surprised you're not using LED to minimize energy use?
Molto Verboso
2007 Stella 225
Joined: 02 Nov 2019
Posts: 1448
Location: Rochester, Minnesota
Mon Feb 15, 2021 8:40 am quote
berto wrote:
Looks clean!

Those look like filament bulbs? I'm surprised you're not using LED to minimize energy use?
Its an led look at January 31 posts.
Molto Verboso
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 1232
Location: Toronto
Mon Feb 15, 2021 8:55 am quote
Christopher_55934 wrote:
berto wrote:
Looks clean!

Those look like filament bulbs? I'm surprised you're not using LED to minimize energy use?
Its an led look at January 31 posts.
I think you mean the headlight? Agreed on that.

I was referring to the tail / brake (/turning?) lights in today's photos.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Mon Feb 15, 2021 3:31 pm quote
berto wrote:
Looks clean!

Those look like filament bulbs? I'm surprised you're not using LED to minimize energy use?
I will be replacing them with LED, once I figure out what to buy. It is surprisingly hard to get a part number on them.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Thu Feb 18, 2021 5:02 am quote
Completed the display wiring and installed the glovebox. Yes, a glovebox. Those swanky Italians!








Anyone see my shame?


Oh, and for those dying to see me paint black, the centerstand!


Hooked
1963 Vespa VBB, 1965 Allstate Cruisaire, 1974 Vespa Super, 2003 Stella 2T
Joined: 31 Jan 2016
Posts: 125
Location: Kansas City
Thu Feb 18, 2021 7:45 am quote
JimVonBaden wrote:
Anyone see my shame?
It's what stickers were invented for....
bodgemaster
63 GL, 76 Super (x 2), 74 Primavera (x 2), 06 Fly 150
Joined: 26 Sep 2013
Posts: 5653
Location: So Cal
Thu Feb 18, 2021 7:57 am quote
Too bad about the scratch. Fortunately it’s in the exact place where the “JVB Productions” decal goes.

You’re pretty close to the finish line. Trim and floor rails?

youtubehd-ysfgKbU_2zM
Hooked
1958 Allstate Super Cruisaire 2005 70cc Yamaha Vino
Joined: 23 Aug 2020
Posts: 220
Location: Philadelphia
Thu Feb 18, 2021 9:03 am quote
Question about the mounting of the rear disc brake:

Wouldn't the stopping power be increased if the brake caliper was on top of the swing arm rather than under it? So that the rotational force was transferred into the frame rather than relying on 2 screws to hold that force?

Or am I overthinking that one?
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Thu Feb 18, 2021 9:29 am quote
Chatis wrote:
JimVonBaden wrote:
Anyone see my shame?
It's what stickers were invented for....
I have some paint left, but that may be the real fix in the end.
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Thu Feb 18, 2021 9:32 am quote
FridayMatinee wrote:
Question about the mounting of the rear disc brake:

Wouldn't the stopping power be increased if the brake caliper was on top of the swing arm rather than under it? So that the rotational force was transferred into the frame rather than relying on 2 screws to hold that force?

Or am I overthinking that one?
The rotational force will be on those two bolts no matter where it is mounted. As for better stopping power, I do not think it matters, though I could be wrong. Being on top would be ideal for bleeding purposes, but I could not find a way to do it without building a new mount, and clearance with the frame would be an issue under compression. I plan to bleed the caliper off the bike and upright.

Thanks,
Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Thu Feb 18, 2021 5:31 pm quote
Nothing glamorous, just installed the centerstand and traced every wire, checked them all to make sure they didn't ground to the body, or mix 12V and 72V in any way, then buttoned it up in the back.


Hooked
P125x (4KW Hub Motor)
Joined: 06 May 2019
Posts: 338
Location: Alexandria, VA
Wed Mar 03, 2021 6:08 pm quote
Work trip, followed by a trip to Daytona. Back at it this weekend.
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