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More pics for input
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bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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First question, what's your overall plan with this project? And what's your budget? The frame can be straightened and cleaned up ... do you want to do a full restoration or just take the dents out and make it rideable?
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Full restoration, frame is already at the straightener, then any additional welding and horncast to start. It will not be perfect, but it will be a driver+

Step 1: cobble it together and ride it up the street ONCE with whatever will make it go. =motivation

Step 2: body and paint, then reassemble with whatever parts make it move down the road. Ride occasionally when I get the hankering (once a month?)

Step 3: replace with correct parts as they become available.

I am in no hurry, I will be keeping this scoot forever, garaged and will ride it occasionally.

Budget is a formula: Desire-patience+cash in my hands+parts availability=budget.

At the end of the day I will spend more than its worth I expect, but it WILL appreciate over time and I get the joy of owning/riding it.

This will be my 5th Vespa (60s 125,70s 90, P200, Rally, 150 Bajaj) I wrenched them all.

I believe this is a unique scooter, deserving of a full resto and I am now mentally married to it, so here we go.
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Have you reached out to Gickspeed or scootermercato for a fork?
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I may be able to help you with some bits and bobs, I am currently in the middle of my resto so I don't know what spares will be around when I am done... but I have a few doubles on items.

Will keep watching your thread and also feel free to thump my ear if I forget to check back in with ya.
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Gick is a no, Mercado doesn't have any listed
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Thank you birds!

I am in TX every few months visiting, so can pick up stuff
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dsnyder586 wrote:
Gick is a no, Mercado doesn't have any listed
Mercado sometimes does not list but well worth calling him.
Last year I had Gick build me a new fork setup and know he had others to choose from, he may get more.
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I like your plan dsnyder! I picked up a project SS last summer & just got it on the road. My plan is similar to yours: get in on the road, enjoy it over the riding season, then paint/body work over the winter.

Keep us posted on progress
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Thanks! I'll definitely keep posting on this thread, should be an interesting ride.
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The Dude
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D - who is doing the frame work?
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Guy in Anaheim.
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Molto Verboso
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dsnyder586 wrote:
Guy in Anaheim.
Did you try Bar Italia? Or Fabio?

There are so many scooter people in Southern California. Might be worth trying the Facebook groups. There might be someone local with a fork.
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The more I look at that frame makes me think you did well. It's in good shape. Try not to settle for a reproduction horncast. Wait it out for an original.
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Is that a thing? Can I find a good used horncast? I would prefer that, but its kind of a center piece so I would need it before I finish the bodywork and paint...
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The Dude
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dsnyder586 wrote:
Guy in Anaheim.
Cool. By chance, Dr John's Motorcycle Frame Straightening? If so, they do good work.

BTW, incase you dont realize; its me Jesse; the guy you procured this frame from I've got lots of answers to your questions, after holding and researching for this frame/model for 20+ years

As for the horn, it is possible to find old original pressings; but fairly uncommon. Ideally you could find wrecked frame someone can chop that piece for you. Repop pressing will be ok if you cant find an original.

As for the metal and patch work, you might consider getting a doneor frame anyway.... or atleast buying a new replacement Tunnel section. That area by the rear brake pedal is extensive, and needs all new metal.

Glad to see you're making progress so quickly. I knew I found the right guy to take over this project
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Yep, Johns. Old school guy all the way. I figured it out it was you when I saw Roseburg lol

Anything we can do in this thread to memorialize info would be great- I am willing to try stuff and report back what does and does not work as well, so hopefully it brings value to others. This frame came on the heels of me finishing the restoration of a 1974 Alfa Spider, which is also a replacement for one I let go and regretted so timing is perfect.

I'll ask around a little, I'll use the repop horncast I have if I dont find a good used one. Its gonna be fast, then slow- When I get it back from straightening, its off to have the tunnel reworked, then I will start the body work in earnest- thats going to take a while.

I'll probably assemble it halfway through the bodywork and make sure everything is lining up correctly, then pull it apart again for final bodywork passes and paint. I'm going to try my hand at metal filler this time and skip the plastic filler whenever possible. I'll drop pics along the way. Much of it depends on cash flow and who has parts and if those two things line up at the same time lol.

V oodoo has been a great resource and ear to bend with my questions, I have to tip my hat to him in appreciation- its nice to have like minded people to work ideas with.

this is a project I am very excited about- My scoot (78 P200 I restored) before the Bajaj was stolen from my carport back in 88 and This is my chance to replace it with something much much better and meaningful to me.
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I don't know for sure, but it might be possible that a Sprint 150 horn cast and the SS180 horn cast are the same. If they are the same dimensions, surely a hacked up Sprint parts bike might be around.
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nomadinsiam wrote:
I don't know for sure, but it might be possible that a Sprint 150 horn cast and the SS180 horn cast are the same. If they are the same dimensions, surely a hacked up Sprint parts bike might be around.
As I have researched this recently as well... can confirm. It appears they are the same profile.
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Style Maven
'74 50s x3 '87 PK125XL '92 PK50XLS Plurimatic - & - '58 AllState '68 Sprint '66(?) Super125 and '72 DanMotor Super150
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Agree, and chances of finding an SS to cut up??? Not good and it seems that the contemporary largeframes all may be the same here. I have been checking the size and it seems a Super might be easier to find than say a Sprint or GL to cannibalize.
SS180 is close by that I will measure soon as I can
SS180 is close by that I will measure soon as I can
Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
Sprint
Sprint
and the Super measures same as the Sprint lengthwise
and the Super measures same as the Sprint lengthwise
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Molto Verboso
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The2 piece horncast for the ss180 was only used on the GL, 1st year Sprint and the SS180. After the ss180 it was changed to accept a hexagon emblem vs the square one.

You can try keeping the top and ordering a hexagon emblem set from SIP.
https://www.sip-scootershop.com/en/product/repair-sheet-horncover_75323700
It looks like the bottom piece has the angles needed for your setup. I can't find the 2 piece horncast repair with the square emblem on SIP.

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His old school panel beater guy can probably remove and straighten the top piece that's already there. That's half of it.
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rowdyc wrote:
You can try keeping the top and ordering a hexagon emblem set from SIP.
This.
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Molto Verboso
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I would actually give Dave a call before doing anything about the horn cover. The picture on their website shows the correct item. Could be a simple mix up between a small frame bottom and a ss180/gl top horn cover. He's a straight up guy and I'm sure he'll make it right.

BTW, great project! I look forward to see how it turns out. Popcorn emoticon
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nomadinsiam wrote:
rowdyc wrote:
You can try keeping the top and ordering a hexagon emblem set from SIP.
This.
This is the answer. The existing original horncast TOP piece is 100% usable. It only has the one dent in the center, easily fixable by body man; and easily welded back on good as new. Same amount of work as buying/triming/welding a new repop...and its the original metal.
No brainer.

The lower piece is the tricky one. Not easy to find the lower piece as a stand alone (original). my 1.5cents - post a want ad on FB and Scoot.net, Photo showing just that horncast piece and your description. In addition also order the repop piece Now, its cheap enough as a plan-B. The way things go, if you wait then no one will have it in stock for 3 months when you do finally need it this week Crying or Very sad emoticon
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Posting for my own reference:

New Zealand assembled 180SS
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Just a quick nod to V oodoo and Geek Lion for stepping up and lending me a hand with parts and knowledge so quickly- My motivation has increased tenfold. (like it needed any increase lol)

She is still at the frame shop, but I will post my work on the other bits until its ready for me to panel beat, and then will post some body shots. What a great group- I have been lurking for about 5 years, glad to now be in the mix~!

For now, here is a couple pics from my last endeavor:
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The Dude
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dsnyder586 wrote:
Just a quick nod to V oodoo and Geek Lion for stepping up and lending me a hand with parts and knowledge so quickly- My motivation has increased tenfold. (like it needed any increase lol)

She is still at the frame shop, but I will post my work on the other bits until its ready for me to panel beat, and then will post some body shots. What a great group- I have been lurking for about 5 years, glad to now be in the mix~!

For now, here is a couple pics from my last endeavor:
Beatiful work! We are here to keep you motivated! You'll be riding 2 wheels in no time Well maybe some time..... and your patience will be worthwhile
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Gorgeous. The split bumper.

I had a 1979. I rebuilt the engine, and replaced the carpet, seat covers and top.

But never painted it, bc a paint job cost twice as much as the car was worth. :)
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Nice! love the cam cover shine. I did all the body and prep work so the spraying was not too expensive.

Gonna do the same loving work on the 180, wish me luck!
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Request:

There are a couple tools that I will need, but do not want to purchase as they will just sit in my garage for years afterwards unused- which will frustrate me.

1. Engine stand- anyone on OC (or close) that would lend/rent me one for a couple months? Could be shorter timeframe depending on my pace.

2. Vice-grip body curve thingy- This would be an easy shipping item, I'll happily pay. Will need for about 1-2 months as well, depending on my speed (which is usually fast based on my impatience)

3. Rivet tool for the rubber channels- I wont need this until the end but I thought I'd put it out there now. Would need it for maybe a week, tops.

I *could* buy these things, but it seems a waste to do so if I will only use them once. (also, I already have a few sets of specialty tools that sit nicely in their boxes and collect dust because I needed them once or twice)
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Moto64 wrote:
To me, what makes the SS so nice is the motor.
Nothing rides like piston ported!
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bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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bodgemaster
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Don't be so sure you're only going to do this once. Just sayin ...
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The Dude
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SoCalGuy wrote:
Don't be so sure you're only going to do this once. Just sayin ...
SoCal's True wisdom has never been more true and wise
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Ok-

*probably* will do this only once. Talk to me in six months and it will change ill bet
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Does anyone have the measurements for a 180SS mud guard? I need to check the one I have-

Thanks!

Dave
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There are some parts listed on "vintage scooter community classifieds" on Facebook.It's a closed group you'll have to join if you haven't already.
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Thank you- I reached out but they only want to trade, not sell.

I very much appreciate the heads up!!
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