Modern Vespa

I've tried everything I could think of on both of these stuck up headsets and they're starting to piss me off. I've anchored an old fork stem in the vise so I'd have something solid to mount to. I've used a couple kinds of penetrant, used propane torch and applied severe torque and pulling force any way I could figure out. I have one of those chain-wrap-ViseGrips to grip and turn w/ plenty of torque after heating the surrounding aluminum - cracked the tube 3 places

On the Sprint headset which I need now, both tubes are frozen in the inner bores only next to the headlight, the outer bores next to the grips are free. It's been many tries over several days and I'm getting discouraged. I've pretty much ruined the throttle tube, several cracks & pretty deformed, but I hope to save the shifter tube.

On the VBA set, I finally got the levers out unbroken and cable remnants, then doused penetrant into all the joints and holes. It's a lot different with more bearing area to get stuck and I've just started on it. Froze solid both sides or it would be back on the VBA.

Now I'm thinking slide hammer, maybe weld connection on to the end of the tube, transmitting the shock and force through the tube pulling it out while the headset is firmly anchored.

Any other ideas?

Thanks.

Can you cut a threaded bar to length, then put a bigger rod over the end with a bolt before it and make your own jack inside the headset? and press it out? use heat or pen. oil while you do it?

You may have to make a plate that the opposite end would press against so you don't just crush the other side of the inside of the headset.. if that makes sense..

it'll work. trust me.

the old "rod with two tubes and a plate internal press" trick!

get a really long flathead screwdriver put the tip on the inside end of the tube (through the headlight hole) and get it really really hot,,the tube and the aloy housing (smoking catching fire etc) and then drive it outwith the hammer n screwdiver

Maybe a homemade slide hammer with a threaded rod and washer/nut combo at the speedo end?

I have used heating and an air chisel with chunks of wood or something to cushion against damage. The vibrations sometimes do the trick. Something like the slide hammer setup would allow using the air chisel to push on the outside end.

Getting it to budge in either direction would help.

No kidding. Its a mild acid and a short soak in vinegar may breakdown whatevers mucking it together.

How are you doing with it?

I appreciate the suggestions and haven't given up.

The main problem with the Sprint headset is there's nothing to push on from inside. You can see here that the shifter side is flush with the inside of the headset, so I would need to have a mandrel turned up that piloted in the tube, with a tiny step to push(or pull) on the thin edge of the tube.

I could use the same mandrel w/ a threaded hole in it & a slide hammer, I like this idea as otherwise I have to weld to the tube end.

I've doused the area w/ vinegar as well as phosphoric acid and the problem seems to be lack of penetration.

I'll try Josh's way on the throttle tube as it's already borked and I've been doing similar there already after getting it to move in about a mm and now it's stuck there, further in. I'll destroy it to get it out if necessary, dremel the id on the stuck end to relieve it. The gear tube I REALLY hope to save.

oh looks like my method will only apply to the older style like vb



how about putting the whole sprint headset in the oven for a few hours

What if you put one tube in the vise vertically (protected with a cloth or something) and push on the other one using the length of the headset as leverage to try to twist and pull out at the same time . I don't know how strong headsets are so I wouldn't want you to snap it. Although I am sure you have tried everything by now.

Don't know if it will fit, but assuming it will... with the headset in the vice like you have it, take a bicycle handlebar gooseneck and install it into the end a tube, then take a long piece of pipe for leverage, and run it through the part of the gooseneck where the handlebars would go. You might be able to twist it out that way.

but I already used these chain ViseGrips to introduce that naughty tube to the concept of severe torque and heat application. Response was these three cracks in the tube before I discovered what was making that interesting 'tingggg' noise THREE times, which I thought was the tube finally coming loose. Nope.

More later today, to be continued...

Have you though about soaking the whole thing in a tub of gas or parts cleaner for a while? It's probably a combination of rust and gummed up grease.

It may be time to sacrifice the tubes to save the headset.

... or this. $6.99 @ HF.

Yep, I conceded the throttle tube earlier, but not sure how I could use that/those bits??? Access issues, it's cramped in there...

More likely a diamond burr in Dremel or Foredom I think, just barely cut thru one spot from inside & I think it'll be relieved enuff for torque, penetrant, various punches & heat to finally win.

But for the gear tube, I'm still gonna try rigging a slide hammer & cross my fingers. Then on to the VBA set which has been soaking in Penetrant

Ka...

ha ha HA.
no
not enuff
did I not mention 'really, REALLY stuck'?



Edit: just had to add a comment when I suddenly saw Bozo the Clown in that Atomic bomb blast. Too weird!

No, but now I'm gonna try soaking end in gallon can of carb cleaner, like RG is using over there. Thanks for the nudge.

Surely a new gear tube is cheaper than repairing a cracked headset while trying to save said tube?? Cut and dremel, Voodoo!

You're right Ginchy, but I wanted to give it one last shot with a slide hammer and another set of hands to help hold on to stuff. The Falcon was available and we set things up nice(didn't even have to weld it ), heated and lubed real good and started slide hammerin' on the throttle side first to see what would happen. Couple minutes later it was loose. Another setup and minutes later the shifter side was out too.

A big THANKS for the helping hand, Hal! And for all the ideas that helped find the final solution.

Love your work as always Voodoo!

Way to show those stuck tubes who's boss.

Phew! very nice Voodoo and friend.

I'm proud to know ya sir!

How I picture Voodoo working on this problem...

Bloody hell, that looked like it took some doing ! Fair play to You m8.

Thanks guys, it was quite the battle! I'm making good progress now and even the throttle tube was OK to use after careful refurbishing.
The nice part is no extreme heat or busted parts, so all that lovely battered original paint is still there to match the rest.

I like the big Euro head light. She's a rusted out Sprint w/ a 16 ga.belly pan and a 3 port Bajaj motor kitted 166, light flywheel, 20/20 carb & SIP Road pipe - an Ameribodge I suppose. So I picked her up a nice set of wings too. Solid polished cast aluminum, none of that stamped out crap.

Voodoo's gone wings!

Fly man fly.. when we gonna get a full line shot of your horses all together? as they are now? you've been such a busy beaver.. lots to see good stuff

That's quite a rig you've got there. Whatever it takes. Good job.

Same here....