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Found a fork! In Italy. Says it NOS. Sans the lower parts, but STILL. Yay.

Also found the lower horncast NOS. also yay.

Frame is *supposed* to be done this weekend, so I can start working on the bodywork!!!!

My son is driving from SEATAC to OC This weekend, so he may be able to courier if anyone needs- PM with any requests, he will be renting a van.

Still looking for lower front end and Cowls. I plan to order the repop swingarm mentioned earlier, so I really should only need the rest of the front.

Its happening folks!
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That's great news. Can't wait to see progress.
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Yes! waiting for the big reveal of stage 1
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Woohoo!

I am still waiting on my horncast! Been almost a month. :-/ (Shipping form Denmark is not quick these days.)
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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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ScooterRaton wrote:
Nothing rides like piston ported!
Fact
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Denmark huh? Oof that's where I am looking.... if its a month I may go crazy. OR, and hear me out, I may get the body near perfect because of how much time I have lol
Birdsnest wrote:
Woohoo!

I am still waiting on my horncast! Been almost a month. :-/ (Shipping form Denmark is not quick these days.)
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Yep, the Ricambi Ebay guy.
He uses ground/ship (as in boat). Think I am at 32 days... yes, I am counting.

*sighs*
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Birdsnest wrote:
Yep, the Ricambi Ebay guy.
He uses ground/ship (as in boat). Think I am at 32 days... yes, I am counting.

*sighs*
Peter is the absolute KING of NOS parts. Just be patient. It'll get there even during a period of plague. I can't put into proper words how valuable a source of parts he has been to me and others over the years.
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He's a gem...

And he posts treasures... truly.
It's kinda like being a kid waiting for Christmas. I am eager, but understand the wait!
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Lost the bid on the horncast. Ugh. $100 seemed like a decent top price for it, but someone wanted it more I suppose.

Looks like the frame will be *straightened* and back to me tomorrow, but I am going to have to figure out the center tunnel.

The guy *could* do it, but he kind of inferred it would be expensive and maybe look ok vs me finding someone who does scooters on the regular so I asked for the frame straightening and all is well.

Maybe I'll build and ride it for a small bit, then tear down and fix the tunnel later this year? Maybe I could give welding a crack and see if I have what it takes? I *did* take metal shop in HS so.....

Time and my patience will tell I guess. After waiting to get it, then waiting while it sat at the frame shop I am loathe to send it off to fix the tunnel- unless I can find local and reasonable....


Off to make my list of parts so I can get a handle on next steps...
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Are Rally, Sprint GL and Super lower horncast sections the same?

First get it back and inspect the tunnel area you are concerned about up good and close. Get a snake cam into the tunnel if you can. Maybe try some paint stripper in those places and /or wire brush cup wheel on and angle head grinder. If there's any cancer, you'll want to do like Safis has done here: A very "Special" project a pretty extreme case fixed right.

But learning how to weld on 180SS could be a problem, sorry... However you might consider doing all of the prep like Safis has done, cut out any rot and fab up the repair panels, get some of them magnets etc..... Then find a good custom auto or muffler shop local, those ppl usually know how to weld pretty and likely have a nice TIG setup too. If you mention that it might be a challenge for just amateur welders, which they are obviously not... If all they gotta do is lay down nice weld with little prep hassle, for all to admire and a quick cash payoff for their best work... WCGW?

External inline image provided by member with no explanatory text

External inline image provided by member with no explanatory text

External inline image provided by member with no explanatory text
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V oodoo wrote:
Are Rally, Sprint GL and Super lower horncast sections the same?
Rally and Sprint are... GL probably too?
(I would have to look at my super.)
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Rally and gl are the same.
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Im toying with the idea of replacing the welded in plate in pieces.

fis the transition part up front, then if I cant make the rest look right tackle the rest.

I have a scope camera so I will shoot that up there and see what I can see
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Super and GL same
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So I picked her up from the frame shop- nice and straight!

It was bent both to the side and to the right, but now is perfectly aligned, happy days. I ended up spending about half what I planned, so that $$ goes into the budget for the last and next batch of goodies.

I am rethinking the center tunnel. I hit it a few times with the body hammer and the transition is not looking to shabby. I *think* I can do some magic with a dremel and grinder to make things look pretty nice and almost all of the top of the tunnel is covered by the rubber pad anyway.

The sides will need a soft touch and a ton of time.

I spent about an hour and a half hammering some dents and am making progress, the frame straightening (as expected) caused some other areas to do funny things so I need to attack them one at a time.

Tomorrow I am going to do a little grinding, a little sanding and a little primering and identify what panels I want to attack in what order.
Better than I expected.
Better than I expected.
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Good News! Sorta

I took a crack at the welds with a flap disk and grinder and made some good progress (step 1)


Then I did a little more and brought in the relief pitcher, mr dremel with a handheld extension and after about 1/2 a day I am pretty encouraged that I can make it a very good looking frame.

I have it at about 75% of where I want it to be, (the tunnel) and I will have a LOT of work on the left side by the floorboard but I think I can salvage the existing work.

LMK your thoughts and dont worry about hurting my feelings, I'm gonna do what I am gonna do anyways lol
Looking good, but I just cant help wondering.. can I do BETTER?
Looking good, but I just cant help wondering.. can I do BETTER?
Whatta ya know? I can salvage the tube.
Whatta ya know? I can salvage the tube.
The floorboard joint is soo cringy. I'll take my sweet time on it.
The floorboard joint is soo cringy. I'll take my sweet time on it.
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WELL, I found out that a GoPro fits nicely into the tunnel for great pics.

I think I am going to get it as close as possible, shoot it with a nice single stage white then ride it. IF someday I FEEL like it I may take it to someone to be properly repaired. OTOH, if it can be fixed properly for less than my left arm, and in a couple days or so maybe I'll get it done.

Here is a pic that covers the *main* weld repair and how the transition is jacked.
Forum member supplied image with no explanatory text
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It looks like somebody cut the lid off your tunnel, did something inside and then welded it back on. I found similar on my ratty old P, and it seems was a good welder. I check there for cracks now and then, but nothing so far after maybe five years. He also welded the broke in half flyside of the motor back together and it runs fine, makes good power and doesn't hardly leak.
uh oh!
uh oh!
but no drama underneath, phew
but no drama underneath, phew
some drama here though, 
who the hell welds broke in half motors back together???
some drama here though, who the hell welds broke in half motors back together???
I'd avoid this kind of thing on any SS motor you find though, bad enough to find a little on your frame
I'd avoid this kind of thing on any SS motor you find though, bad enough to find a little on your frame
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UTC quote
Someone really wanted to save those cases!
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UTC quote
The welding on that tunnel is horrid, should be cut out and fixed. My welding sucks and that person is worse than me. Makes me feel a bit better about my poor out of practice skills.

Is that a period correct Allstate badge or a repop? I ordered a repop from Singapore just to have something.
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UTC quote
swiss1939 wrote:
Someone really wanted to save those cases!
Could have at least cleaned them up when finished.
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Fork coming UPS tomorrow!!!! Now I just need bearings etc.
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Thats great news!
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Maybe I am crazy, but is it possible that the horncast is the correct one, and just was stamped not fully? I want to get this painted before June, so Id like to get it welded.

See how it has that little peak at the top? Seems like just a poor stamping

I need guidance on this one

Thanks!

Dave
It *seems* to be pretty close
It *seems* to be pretty close
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looks like a not so crisp stamping. That peak and details should be more defined and sharp. See this NOS example of horn mount portion below. (it has been spray painted yellow primer)
Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
⚠️ Last edited by GeekLion on UTC; edited 1 time
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GeekLion is right, it should have three distinct ridges. See pic of GL below.

The ridges seem to have gotten a little softer in later years ... or maybe the stamping machines just started wearing out lol.
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Sorry the lower is incorrect

It seems SIP bungled their website and were sending smallie style lowers with the correct upper bit.

It will never really look right imho.

I'd keep searching for a donor scoot or try and source a good/proper repop.
Worth waiting for the right bit.
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Listen to Jeff.
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And here is an original on an SS. Ideally you will have four horn screw locations, not three.
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UTC quote
Thanks for the good eyes, I will begin the search for the correct one and use the extra time to focus on the rest of the body
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UTC quote
These photo comparisons really show how horrid reproduction stampings are compared to original stampings. That smallie horncast looks putrid. There aren't even any screw holes. As Voodoo has said, an SS180 horncast has four holes as seen below (four screws).

[img][/img]
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Sounds redundant, but does anyone have a line on a horncast? I'd like to get it put on with the rest in the next week or so.
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Free to a good home

It's rough and would take a good and patient welder but if ya want it holler...
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I found one in NZ, so i *should* get one, but nothing is for sure until it arrives on my dooorstep...

Here is a little progress for those following- I've got the brake tube about 90% done and starting the bodywork.
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UTC quote
Is it worth giving the frame a wash before you go much further?
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UTC quote
I love both of these SS180 projects.
I'm still putting final touches on mine. The stator coils I put on it are crap (won't mention the source), so now I'm waiting on a whole new set.
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Hi Matchless-

I was planning on washing after teh main welding was complete, but I think I'll do so today.

Pics to follow
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Ok- updates and pictures!

I cut out some of the welded area- it does not look as bad as I thought. Any ideas how I should attack this? I will likely do most of the cutting and fitting for the welder and they can wrap it up.
Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
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