Mon Jul 04, 2022 9:10 pm

Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
 
Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
Mon Jul 04, 2022 9:10 pm linkquote
your will likely fit better than my originals do.
Mon Jul 04, 2022 9:17 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Mon Jul 04, 2022 9:17 pm linkquote
FINYoshi wrote:
It's no surprise that the floor rails did not fit out of the box.

In my GL build I had the holes lined up on two out of six rails. Others had to be cut and re-drilled to make them fit. Of course the shape was also just a starting point.

Good job!
This is the hardest part so far! Rebuilding the engine is nothing!
Mon Jul 04, 2022 10:54 pm

Hooked
Parmakit Primavera -74, Polini Primavera -68, Stock 150 Touring -59, VMC 177 Bajaj Chetak 125 -95
Joined: 22 Jun 2022
Posts: 420
Location: Finland
 
Hooked
Parmakit Primavera -74, Polini Primavera -68, Stock 150 Touring -59, VMC 177 Bajaj Chetak 125 -95
Joined: 22 Jun 2022
Posts: 420
Location: Finland
Mon Jul 04, 2022 10:54 pm linkquote
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
Tue Jul 05, 2022 4:38 am

Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: 16 Jun 2011
Posts: 6553
Location: Nashville
 
Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: 16 Jun 2011
Posts: 6553
Location: Nashville
Tue Jul 05, 2022 4:38 am linkquote
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...
Sat Jul 23, 2022 8:07 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Sat Jul 23, 2022 8:07 pm linkquote
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.


ok. Rails. This works.






I think I can fix this with a foam spacer inside, or tweaking the shape a little.


This is bad.


Yikes.



Sun Jul 24, 2022 2:32 am

Hooked
Yellow GTS 300 Super, Black GTS 300 Super Sport, Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special
Joined: 14 Aug 2020
Posts: 226
Location: London
 
Hooked
Yellow GTS 300 Super, Black GTS 300 Super Sport, Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special
Joined: 14 Aug 2020
Posts: 226
Location: London
Sun Jul 24, 2022 2:32 am linkquote
There is some forgiveness in the rubber trim. Try dry fitting it too to see if it helps with the gap.
Sun Jul 24, 2022 4:19 am

Not So Moderator
VNB vsc o9c VMA vbc VSX
Joined: 28 May 2008
Posts: 6413
Location: Hustletown, TX
 
Not So Moderator
VNB vsc o9c VMA vbc VSX
Joined: 28 May 2008
Posts: 6413
Location: Hustletown, TX
Sun Jul 24, 2022 4:19 am linkquote
Agree, the rubber trim will help!
Sun Jul 24, 2022 6:17 am

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 311
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 311
Location: San Francisco Bay Area
Sun Jul 24, 2022 6:17 am linkquote
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 !
Sun Jul 24, 2022 6:26 am

Molto Verboso
Joined: 14 Oct 2016
Posts: 1171
Location: northern New York
 
Molto Verboso
Joined: 14 Oct 2016
Posts: 1171
Location: northern New York
Sun Jul 24, 2022 6:26 am linkquote
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.
Sun Jul 24, 2022 6:53 am

Veni, Vidi, Posti
Joined: 22 Oct 2011
Posts: 5153
Location: Tega Cay, SC
 
Veni, Vidi, Posti
Joined: 22 Oct 2011
Posts: 5153
Location: Tega Cay, SC
Sun Jul 24, 2022 6:53 am linkquote
orwell84 wrote:
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.
Sun Jul 24, 2022 6:54 am

Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
 
Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
Sun Jul 24, 2022 6:54 am linkquote
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.
Sun Jul 24, 2022 11:13 am

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Sun Jul 24, 2022 11:13 am linkquote
Ok. Thanks! I'll order the rubber trim. Hopefully it's forgiving.
Sun Jul 24, 2022 11:30 am

Ossessionato
79 P200E (Ruby), 62 Allstate (B-62), 2008 Stella (Olive)
Joined: 11 Jan 2006
Posts: 3171
Location: Florence, OR
 
Ossessionato
79 P200E (Ruby), 62 Allstate (B-62), 2008 Stella (Olive)
Joined: 11 Jan 2006
Posts: 3171
Location: Florence, OR
Sun Jul 24, 2022 11:30 am linkquote
hjo wrote:
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...
Sun Jul 24, 2022 1:51 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Sun Jul 24, 2022 1:51 pm linkquote
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.



Sun Jul 24, 2022 2:49 pm

Molto Verboso
Joined: 14 Oct 2016
Posts: 1171
Location: northern New York
 
Molto Verboso
Joined: 14 Oct 2016
Posts: 1171
Location: northern New York
Sun Jul 24, 2022 2:49 pm linkquote
And that too…I think it will fit better when it bolted on. The bolts probably take up some flex. it the glovebox.
Wed Jul 27, 2022 2:37 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Wed Jul 27, 2022 2:37 pm linkquote
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!











Wed Jul 27, 2022 3:58 pm

Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 311
Location: San Francisco Bay Area
 
Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
Joined: 08 Feb 2020
Posts: 311
Location: San Francisco Bay Area
Wed Jul 27, 2022 3:58 pm linkquote
looking great man!
Wed Jul 27, 2022 6:19 pm

Hooked
1974 Rally (3), 1971 Rally 180, 1960 Li 125
Joined: 20 Mar 2014
Posts: 426
Location: Southern California, USA
 
Hooked
1974 Rally (3), 1971 Rally 180, 1960 Li 125
Joined: 20 Mar 2014
Posts: 426
Location: Southern California, USA
Wed Jul 27, 2022 6:19 pm linkquote
Go man, go!
Thu Jul 28, 2022 7:42 am

Not So Moderator
VNB vsc o9c VMA vbc VSX
Joined: 28 May 2008
Posts: 6413
Location: Hustletown, TX
 
Not So Moderator
VNB vsc o9c VMA vbc VSX
Joined: 28 May 2008
Posts: 6413
Location: Hustletown, TX
Thu Jul 28, 2022 7:42 am linkquote
*wolf eyes*
*Sound of antique horn*

Get that thing to paint!
Thu Jul 28, 2022 2:40 pm

Style Maven
'74 50s x3 '78 P200 E '84 Cosa '91 PK50XL2 '58 AllState '68 Sprint '80 50special and a '66(?) Super125
Joined: 22 Nov 2010
Posts: 8798
Location: seattle/athens
 
Style Maven
'74 50s x3 '78 P200 E '84 Cosa '91 PK50XL2 '58 AllState '68 Sprint '80 50special and a '66(?) Super125
Joined: 22 Nov 2010
Posts: 8798
Location: seattle/athens
Thu Jul 28, 2022 2:40 pm linkquote
Dry fitting all your trim and glove box etc BEFORE paint, now that's smart.
Also makes your bike look like a million bucks!
Thu Jul 28, 2022 8:45 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Thu Jul 28, 2022 8:45 pm linkquote
V oodoo wrote:
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!
Thu Jul 28, 2022 8:45 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Thu Jul 28, 2022 8:45 pm linkquote
ok.. Coming along.


Six floor rails!


They're all there. And look right. It's so much easier when the holes are there. Placing them was scary.


I has this powder coated with a batch. It was super rusty.


I wonder if I should save it. Those springs on the top are probably worn out?


This repro seat looks pretty nice, but doesn't show the frame.


There's also the cover. This one doesn't have the white stiching, but does have the rivet, and really dark blue instead of black.


They also sell the foam. There's a piece of rubber between the springs and foam I am missing.

Fri Jul 29, 2022 12:26 am

The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1442
Location: PNW from LBC
 
The Dude
Too Many piles of Junk that need too much work and too much money
Joined: 06 May 2019
Posts: 1442
Location: PNW from LBC
Fri Jul 29, 2022 12:26 am linkquote
Looking real good!! Chipping away
Fri Jul 29, 2022 7:53 am

Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
 
Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
Fri Jul 29, 2022 7:53 am linkquote
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.
Fri Jul 29, 2022 8:07 am

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Fri Jul 29, 2022 8:07 am linkquote
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.


This mat under the seat.



Fri Jul 29, 2022 8:11 am

Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
 
Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
Fri Jul 29, 2022 8:11 am linkquote
craft store or sewing store might be the easiest
Fri Jul 29, 2022 8:33 am

Molto Verboso
1958 Allstate 177VMC, 2005 70cc Yamaha Vino
Joined: 23 Aug 2020
Posts: 1104
Location: Philadelphia
 
Molto Verboso
1958 Allstate 177VMC, 2005 70cc Yamaha Vino
Joined: 23 Aug 2020
Posts: 1104
Location: Philadelphia
Fri Jul 29, 2022 8:33 am linkquote
sdjohn wrote:
craft store or sewing store might be the easiest
Agreed. They'll have the foam you need.
Fri Jul 29, 2022 9:00 am

Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
 
Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
Fri Jul 29, 2022 9:00 am linkquote
probably a scrap of vinyl would do over the springs, and they will have that also
Fri Jul 29, 2022 9:28 am

Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
 
Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
Fri Jul 29, 2022 9:28 am linkquote
measured the rubber sheet on Rally seat, it's 3mm thick. The GS is 5mm thick and has a waffle texture.
Fri Jul 29, 2022 9:32 am

Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
 
Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 6532
Location: San Diego, CA
Fri Jul 29, 2022 9:32 am linkquote
oopsclunkthud wrote:
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
Fri Jul 29, 2022 9:45 am

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Fri Jul 29, 2022 9:45 am linkquote
oopsclunkthud wrote:
measured the rubber sheet on Rally seat, it's 3mm thick. The GS is 5mm thick and has a waffle texture.
Thank you!

I'll save the seat frame. Might as well, I had it powder coated.
Fri Jul 29, 2022 9:55 am

Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
 
Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
Fri Jul 29, 2022 9:55 am linkquote
McMaster has it too. one example: https://www.mcmaster.com/8634K318/
Fri Jul 29, 2022 12:07 pm

Ossessionato
2007 Stella 225
Joined: 02 Nov 2019
Posts: 3059
Location: Rochester, Minnesota
 
Ossessionato
2007 Stella 225
Joined: 02 Nov 2019
Posts: 3059
Location: Rochester, Minnesota
Fri Jul 29, 2022 12:07 pm linkquote
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.
Fri Jul 29, 2022 1:00 pm

Molto Verboso
Joined: 14 Oct 2016
Posts: 1171
Location: northern New York
 
Molto Verboso
Joined: 14 Oct 2016
Posts: 1171
Location: northern New York
Fri Jul 29, 2022 1:00 pm linkquote
Just out of curiosity. How do a Rally and a VBB compare in terms of size of the frame? Compared to a P series?
Fri Jul 29, 2022 1:10 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Fri Jul 29, 2022 1:10 pm linkquote
orwell84 wrote:
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.
Fri Jul 29, 2022 1:36 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Fri Jul 29, 2022 1:36 pm linkquote
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.








All for of these are different, but all called battery buffer for a rally. ???? Not sure which, or if there are multiple.



Fri Jul 29, 2022 4:37 pm

Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
 
Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
Fri Jul 29, 2022 4:37 pm linkquote
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.



Fri Jul 29, 2022 5:02 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Fri Jul 29, 2022 5:02 pm linkquote
oopsclunkthud wrote:
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!!!
Fri Jul 29, 2022 5:05 pm

Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
 
Banned
2:6
Joined: 11 Jan 2007
Posts: 8310
Location: San Francisco
Fri Jul 29, 2022 5:05 pm linkquote
the bottom bolt on the regulator also has a rubber lined metal clamp that holds the wires going to the battery and flasher.



Fri Jul 29, 2022 5:20 pm

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
 
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: 30 Jul 2009
Posts: 1658
Location: San Francisco, CA
Fri Jul 29, 2022 5:20 pm linkquote
This is so helpful! Thank you!
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