Modern Vespa

your will likely fit better than my originals do.

This is the hardest part so far! Rebuilding the engine is nothing!

This might be the hardest, but the most annoying part is to join the cases. At least on a early engine with those skinny ball bearings on both sides of the crankshaft. Heating up the other half, another in the freezer. Join the cases - something binds. Rinse and repeat, does not go all the way in. Rinse and repeat, notice that the kickstarter small gear is still on the table. Rinse and repeat...

Learned the hard way

What's funny is that having just split cases on a Sprint (old-style bearings) and LML/PX (two-piece fly side bearing), after warming the bearing race with a heat gun the Sprint motor basically fell back together like it was the easiest thing in the world. I was ready for all manner of wrestling and crank pulling and didn't need to do a bit of it.

The LML/PX motor, on the other hand, was a freakin' nightmare to get back together. Something just didn't want to seat right every time. The big difference, I think, is that the SprintV motor was on the bench so I could turn it on its side, so no lateral forces (gravity) on the shafts, whereas the LML was still in the bike.

At least I didn't leave my kickstarter gear on the bench and not notice until after I'd completed re-assembly and pressure tested the motor...this time...

I am so close. Time to finish this thing.

Finally got the rails, which were really frustrating.

Dry fitting the glovebox, there's a bit of a gap there. The shape of the legshield now has changed a little. The legshield comes in a bit more at the bottom, which is not noticeable, bit it is when you mount the glovebox.

I am not sure how to approach this. I can either belt sand off a bit of material on the glove box to match the legshield, or try to pound out the legshield, maybe with a rubber mallet.

There is some forgiveness in the rubber trim. Try dry fitting it too to see if it helps with the gap.

Agree, the rubber trim will help!

When I first installed an sip glove box on my ss frame that had a rough life, I had about the margins you are showing. I thought no way could this work but that rubber trim covered all the gaps !

I think the rubber is made to take up that space. It does on my p bikes. You are well into that phase where things all tend to look like potential flaws. Just keep going. That bike's gonna all come together and look really sweet.

My Rally was like that from the factory, once the rubber trim was on, it looked good enough. Also works to keep the rattling down.

I need to pull the glovebox off my rally today anyhow. I'll snap a shot of how it lines up without the rubber trim.

Ok. Thanks! I'll order the rubber trim. Hopefully it's forgiving.

You don't have the rubber trim yet??

You're gonna have a super sweet ride here shortly! Keep up the good work...

I just ordered the rubber trim from Scooterwest. Should get it wednesday.

Super excited that the German shops have these things. Repro screws for the bottom of the glovebox. Mine were destroyed.

And that too…I think it will fit better when it bolted on. The bolts probably take up some flex. it the glovebox.

Look at that. With the rubber and mounting hardware, it's fine.

ok!

So I just have to fill four holes where I put the end caps wrong, and do a final wet sand!

looking great man!

Go man, go!

*wolf eyes*
*Sound of antique horn*

Get that thing to paint!

Dry fitting all your trim and glove box etc BEFORE paint, now that's smart.
Also makes your bike look like a million bucks!

I was worried it wouldn't fit after replacing all that metal!

ok.. Coming along.

Looking real good!! Chipping away

I think you can source springs if any fail. I'm always for saving OG parts if they look usable, and that one certainly does.

I'll try to save it. Much cheaper, too.

The german shops have all the parts – the clips and rubber buffers.

The only things they don't have are this black rubber mat that goes above the springs and a thin piece of foam that goes above the seat padding.

I'm sure the rubber mat is something I could buy on Amazon, but don't know what it's called.

craft store or sewing store might be the easiest

Agreed. They'll have the foam you need.

probably a scrap of vinyl would do over the springs, and they will have that also

measured the rubber sheet on Rally seat, it's 3mm thick. The GS is 5mm thick and has a waffle texture.

you can get rubber sheeting thick like that at home depot

Thank you!

I'll save the seat frame. Might as well, I had it powder coated.

McMaster has it too. one example: https://www.mcmaster.com/8634K318/

That plastic or rubber, looks like it's purpose is to ride on top of springs and protect foam from springs. Just needs to be stiff enough to not get torn up by springs.

Just out of curiosity. How do a Rally and a VBB compare in terms of size of the frame? Compared to a P series?

They're all the same size, as far as I know. The older ones are a bit bigger (if you're trying to fit in a car) bc the tail and horncast extend out longer.

ok.

Since I'm ordering from Germany, want to make sure I have all these parts.

I think I have all these correct. Lots of grommets for wires, and then there are four styles for battery buffers, and not sure which are used.

The hole behind the battery is a tall buffer (top left in your picture).
the 3 holes in the base of the battery tray are the bottom left buffer in your picture.
The hole above the flasher is nothing that I know of.

The hole in the bottom left side of the battery tray is not present on mine. you should weld it up before someone knocks points off for an incorrect restoration.

Thank you so much!!!

the bottom bolt on the regulator also has a rubber lined metal clamp that holds the wires going to the battery and flasher.

This is so helpful! Thank you!