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@hjo avatar
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
@hjo avatar
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UTC quote
Weird. This one isn't on my other rally frame either.

Someone did a number on the battery tray. They pried it out to fit a larger battery that was held with a bungee cord or something
Forum member supplied image with no explanatory text
Other frame.
Other frame.
Forum member supplied image with no explanatory text
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@hjo avatar
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
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UTC quote
All done and ready to paint.

Just one fix left. Need to weld up the holes from where I did the rails wrong.
The nose is symmetrical now.
The nose is symmetrical now.
So sad. Bad mistake. I could have the paint shop fix this, I guess.
So sad. Bad mistake. I could have the paint shop fix this, I guess.
10 Pieces, right? Frame, tank, headset (2), glovebox (2), cowls (2), fender, taillight bracket.
10 Pieces, right? Frame, tank, headset (2), glovebox (2), cowls (2), fender, taillight bracket.
⚠️ Last edited by hjo on UTC; edited 1 time
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Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
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Hooked
@cdevillasante avatar
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UTC quote
looks great, I agree have the paint shop fix that and keep forward motion!
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@hjo avatar
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
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UTC quote
ok. Saving the seat.

I found that you can order literally every piece from Mauro Pascoli in Italy. So the rest are arriving Friday or Saturday. Amazing.

I'm getting all the parts. New springs too.

Bike's ready to paint. Taking it to the shop next week!!
Exciting rubber parts. They have the US horn gasket, bc it's also used in Germany.
Exciting rubber parts. They have the US horn gasket, bc it's also used in Germany.
The seat frame looks pretty good. It was super rusty, and had it powder coated.
The seat frame looks pretty good. It was super rusty, and had it powder coated.
This patina is amazing. It was all rusty and pitted, but very heavy steel. It has a kind of cast iron texture, and is all clean and shiny.
This patina is amazing. It was all rusty and pitted, but very heavy steel. It has a kind of cast iron texture, and is all clean and shiny.
Forum member supplied image with no explanatory text
Love the cleaned up pitting.
Love the cleaned up pitting.
This latch is supposed to have a return spring, but I have no idea what it looks like or where it goes.
This latch is supposed to have a return spring, but I have no idea what it looks like or where it goes.
New feet. I guess these just sit in there? There are no clips to hold them, but they're pretty tight fit.
New feet. I guess these just sit in there? There are no clips to hold them, but they're pretty tight fit.
I bought this may, but it's too short. Luckily, there's one from Pascoli on the way.
I bought this may, but it's too short. Luckily, there's one from Pascoli on the way.
Seat foam. I guess there's just this foam and the mat. Nothing on top?
Seat foam. I guess there's just this foam and the mat. Nothing on top?
Forum member supplied image with no explanatory text
I am in love with this stuff. Found the correct glove box screws, rivets for the number plate, seat clips.
I am in love with this stuff. Found the correct glove box screws, rivets for the number plate, seat clips.
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UTC quote
I love watching this kind of restoration with such attention to detail. What makes it even more special is that even though you just learned some of these skills, you have done excellent work. The frame tunnel was a particularly hard project to go to school on.

Im excited for you, for when you get it in paint. It's a magical day seeing a vehicle in fresh paint for the first time. I'm looking forward to it.
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UTC quote
Good stuff...

Where did you source the glovebox screws?
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UTC quote
how soft is that foam?

I got a Pascoli seat for my GS and while it looks perfect and is made very well, the foam was just soft open cell and is uncomfortable as hell.

The stock seat on my GS and Rally are very comfortable even on 350 mile rides.

If the foam provided is soft it could still be used as a pattern. I'm sure a foam shop would have a close match to the original.
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
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UTC quote
Birdsnest wrote:
Good stuff...

Where did you source the glovebox screws?
These were from Scooter Center.

I discovered that Pascoli had parts that Scooter Center didn't have, or I couldn't find, so bought some directly from them, too.

https://www.mauropascoli.it/
Forum member supplied image with no explanatory text
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Molto Verboso
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Molto Verboso
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UTC quote
oopsclunkthud wrote:
how soft is that foam?

I got a Pascoli seat for my GS and while it looks perfect and is made very well, the foam was just soft open cell and is uncomfortable as hell.

If the foam provided is soft it could still be used as a pattern. I'm sure a foam shop would have a close match to the original.
That's a good idea! I'll go that. There's an auto upholstery place on Geary/Masonic (near me).

This foam looks like the same one Pascoli sells. I got it from Scooter Center.

It's not great. It collapses to almost flat between my fingers. It doesn't look like it would be comfortable.

The original seats I've replaced the covers on, have two layers of foam. One that is pretty dense and molded so the edges are round, then a soft, thinner layer on top, and I believe a light layer of plastic film between that and the seat cover.
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2007 Stella 225
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UTC quote
hjo wrote:
That's a good idea! I'll go that. There's an auto upholstery place on Geary/Masonic (near me).

This foam looks like the same one Pascoli sells. I got it from Scooter Center.

It's not great. It collapses to almost flat between my fingers. It doesn't look like it would be comfortable.

The original seats I've replaced the covers on, have two layers of foam. One that is pretty dense and molded so the edges are round, then a soft, thinner layer on top, and I believe a light layer of plastic film between that and the seat cover.
Plastic film is to keep water from soaking into foam in case seat gets wet.

Seat shop should be able to get you a foam you can form and trim with an electric knife like you use for cutting meat, you can also use a hot knife.

If you have an old seat cover they can trace it and stitch you a new cover.
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UTC quote
hjo wrote:
These were from Scooter Center.

I discovered that Pascoli had parts that Scooter Center didn't have, or I couldn't find, so bought some directly from them, too.
TY. I have local specialty shop I may check with, but thats great to have a back up with the flat heads.
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bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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UTC quote
Soft foam is no good for a seat. If you're going to an upholstery shop, get the firmest they have. The springs supply the cushioning.
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
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UTC quote
Seat parts.

Going to the upholstery shop to see if there is better foam, but the other parts look good!
The mat
The mat
Piaggio stamp. Is that what the original ones look like?
Piaggio stamp. Is that what the original ones look like?
Forum member supplied image with no explanatory text
The seat cover and strap are not quite black, but a very dark blue. Just like the original ones.
The seat cover and strap are not quite black, but a very dark blue. Just like the original ones.
There are 10 springs. This is enough for 4 of them. :(  Scooterwest also has these, but I doubt they match.
There are 10 springs. This is enough for 4 of them. :( Scooterwest also has these, but I doubt they match.
I love that they have the right strap screws and the little rivet button on the back. No clue how that works, though.
I love that they have the right strap screws and the little rivet button on the back. No clue how that works, though.
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@hjo avatar
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Molto Verboso
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Molto Verboso
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UTC quote
Went to the upholstery shop, and they had exactly the same foam. Interesting.

Seems like there are a couple of options.

1. Something same dimension but higher density
2. A higher density, thinner piece of foam, and keeping the current one on top
3. Gel pads as a lowr layer look interesting, but they're too expensive
High density
High density
This as a lower layer looks like it could work
This as a lower layer looks like it could work
These are SO expensive. They're made for motorcycle seats, but in small sizes. one big enough for 26x12" or so is like $200.
These are SO expensive. They're made for motorcycle seats, but in small sizes. one big enough for 26x12" or so is like $200.
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Hooked
Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special
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I used neoprene (wet suit material) on one of my seats. I think it was 20mm thick and fairly easy to cut.
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@hjo avatar
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
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Was neoprene comfortable?
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79 P200E (Ruby), 62 Allstate (B-62)
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I used half inch yoga mat
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Hooked
Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special
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UTC quote
hjo wrote:
Was neoprene comfortable?
Yea it was.
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
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UTC quote
More seat things.
I noticed the spring hooks are so worn, they're about to break. This bike definitely got some use.
I noticed the spring hooks are so worn, they're about to break. This bike definitely got some use.
Those aren't something you can buy, so making some out of whatever these are.
Those aren't something you can buy, so making some out of whatever these are.
Not too bad. The old ones in the right are all rusty, too.
Not too bad. The old ones in the right are all rusty, too.
Shiny things you never see.
Shiny things you never see.
Random spring from the hardware store works for the seat latch.
Random spring from the hardware store works for the seat latch.
These and the frame are the only original seat parts left.
These and the frame are the only original seat parts left.
New hardware. I labor over things like this. Neither is exact. The right one looks more original, but it's a SAE size. The phillips ones kind of look nicer. They're stainless and metric.
New hardware. I labor over things like this. Neither is exact. The right one looks more original, but it's a SAE size. The phillips ones kind of look nicer. They're stainless and metric.
The original hardware. Looks gross. Is it worth keeping it flat head? The only one who will know it's not metric is me.
The original hardware. Looks gross. Is it worth keeping it flat head? The only one who will know it's not metric is me.
If you order these springs, be warned. You need two or three of the packs to do all the springs. I have to wait for them to come in the mail before assembling.
If you order these springs, be warned. You need two or three of the packs to do all the springs. I have to wait for them to come in the mail before assembling.
I ordered a 1/4" sheet of neoprene to go under the foam. 

lol. This is costing more than a replacement seat. But I think it will be perfect. I like saving the original frame.
I ordered a 1/4" sheet of neoprene to go under the foam. lol. This is costing more than a replacement seat. But I think it will be perfect. I like saving the original frame.
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Oval head screw would look really nice there.
https://www.mcmaster.com/91790A460/

more slotted options:
https://www.mcmaster.com/catalog/128/3357
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another foam source, but don't have prices listed:
FS4L Seat foam sheet 3/4" - long 12x26"

edit: price list is at the bottom of the page.
⚠️ Last edited by oopsclunkthud on UTC; edited 1 time
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UTC quote
hjo wrote:
More seat things.
Hmm.. here I am just spraying the rusty original frame with ospho and calling it a day.

Now you got me wanting to pull it all apart, soak in some vinegar to eat the rust away and then paint and restore completely!

The one thing I'm looking for to replicate original is a stiff leather base for the stiff foam.
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Molto Verboso
Scattered remnants of (two!) 1974 Rallys
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Molto Verboso
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UTC quote
oopsclunkthud wrote:
Oval head screw would look really nice there.
https://www.mcmaster.com/91790A460/

more slotted options:
https://www.mcmaster.com/catalog/128/3357
Thanks for these! These look really nice, but they come in packs of 50!

Do you know if there's a hardware store in SF that sells them in bins?

I'm kind of amazed at how much of this type hardware you can find at hardware stores. The ones I found were just from a corner hardware store, and drawers with things that have probably been there for decades.
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Molto Verboso
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Molto Verboso
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UTC quote
swiss1939 wrote:
The one thing I'm looking for to replicate original is a stiff leather base for the stiff foam.
Is this what you mean? I bought this from Mauro Pascoli. It was like $12.

https://www.mauropascoli.it/?lang=en#

The site is a bit hard to navigate, but they have every seat part. And they delivered from Italy in three days!
Forum member supplied image with no explanatory text
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hjo wrote:
Is this what you mean? I bought this from Mauro Pascoli. It was like $12.

https://www.mauropascoli.it/?lang=en#

The site is a bit hard to navigate, but they have every seat part. And they delivered from Italy in three days!
Yep, thats the part.
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UTC quote
hjo wrote:
Thanks for these! These look really nice, but they come in packs of 50!

Do you know if there's a hardware store in SF that sells them in bins?

I'm kind of amazed at how much of this type hardware you can find at hardware stores. The ones I found were just from a corner hardware store, and drawers with things that have probably been there for decades.
What's the thread (M6?) and length needed?

I'll gladly order them and create a bin for the 48 left over.
OP
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Molto Verboso
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Molto Verboso
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UTC quote
oopsclunkthud wrote:
What's the thread (M6?) and length needed?

I'll gladly order them and create a bin for the 48 left over.
I'm not sure the M size. It's the same thread as the bolts for the seat/tank on a Rally (with 11mm bolts)

These ones look perfect. I ordered them.
⚠️ Last edited by hjo on UTC; edited 1 time
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@sdjohn avatar
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OP
@hjo avatar
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Molto Verboso
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Molto Verboso
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UTC quote
sdjohn wrote:
get a cheapo thread guage card from home despot or amazon and attach it to your toolbox with a magnet. very handy..
This looks good!
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Nice! You are well beyond the level of detail I have put into projects so I am enjoying watching your progress. On my list but not there yet.
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hjo wrote:
This looks good!
the ones at Home Depot are thinner but cost like $1
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UTC quote
hjo wrote:
Is this what you mean? I bought this from Mauro Pascoli. It was like $12.

https://www.mauropascoli.it/?lang=en#

The site is a bit hard to navigate, but they have every seat part. And they delivered from Italy in three days!
Here is the actual part:
https://www.mauropascoli.it/scheda.php?id=13025.jpg
OP
@hjo avatar
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Molto Verboso
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UTC quote
swiss1939 wrote:
Yes! That's the right one for a P seat. And they have all the other parts in the related section there. Molded foam and all.

The exchange rate is good right now, and shipping wasn't too bad.
OP
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Molto Verboso
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UTC quote
I am making such a production.

Should have all the seat parts tomorrow. Just waiting on more springs.

Kind of liking the rebuild original seat.
These things arrived in one day!
These things arrived in one day!
Perfect.
Perfect.
Before. Really happy I had this photo to see how things go. Realized these hook on the second loop.
Before. Really happy I had this photo to see how things go. Realized these hook on the second loop.
The domed screws look nice.
The domed screws look nice.
Neoprene. This foam is super nice.
Neoprene. This foam is super nice.
Forum member supplied image with no explanatory text
I have enough left over to do a second sheet, and sandwich the light foam. Hopefully it's not too thick. The neoprene is just a quarter inch.
I have enough left over to do a second sheet, and sandwich the light foam. Hopefully it's not too thick. The neoprene is just a quarter inch.
Ran out of springs. :) This is what one pack gets. It's just 9 of 19. So I need three packs.
Ran out of springs. :) This is what one pack gets. It's just 9 of 19. So I need three packs.
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The Dude
Too Many piles of Junk that need too much work and too much money
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Really great work on the seat. Nice attention to detail
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Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate
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UTC quote
hjo wrote:
I am making such a production.

Should have all the seat parts tomorrow. Just waiting on more springs.

Kind of liking the rebuild original seat.
This is how parts dragon hoards happen. Embrace the dark side!
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Hooked
1979 P200, 1960 Lambretta s2, 1975 Rally 200
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UTC quote
when we are both done with our builds and we finally go for a ride, my rally will be the ratty cousin! Razz emoticon I actually have to redo my seat too so great to have this thread as reference
OP
@hjo avatar
UTC

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: UTC
Posts: 1845
Location: San Francisco, CA
 
Molto Verboso
@hjo avatar
Scattered remnants of (two!) 1974 Rallys
Joined: UTC
Posts: 1845
Location: San Francisco, CA
UTC quote
Cdevillasante wrote:
when we are both done with our builds and we finally go for a ride, my rally will be the ratty cousin! Razz emoticon I actually have to redo my seat too so great to have this thread as reference
I'm happy I saved the seat!

This one looks nice, if you're looking for a complete one.

All the parts added up to maybe half this much.
Forum member supplied image with no explanatory text
OP
@hjo avatar
UTC

Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: UTC
Posts: 1845
Location: San Francisco, CA
 
Molto Verboso
@hjo avatar
Scattered remnants of (two!) 1974 Rallys
Joined: UTC
Posts: 1845
Location: San Francisco, CA
UTC quote
This thing is such an ordeal.

Finally dropped off the bike to paint, though.

Seat.
Sprung.
Sprung.
This rubber piece doesn't cover all the springs.
This rubber piece doesn't cover all the springs.
The screws look nice, but have to remove them and trim the length. when the seat is pushed down, they touch.
The screws look nice, but have to remove them and trim the length. when the seat is pushed down, they touch.
ok. That looks wrong. Luckily I have enough spring to redo the two outer ones in front. They're too tight.
ok. That looks wrong. Luckily I have enough spring to redo the two outer ones in front. They're too tight.
This bar thing. I know it goes around here. I think to push out these springs. This look right?
This bar thing. I know it goes around here. I think to push out these springs. This look right?
@rallygeek avatar
UTC

Hooked
Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special
Joined: UTC
Posts: 384
Location: Melbourne
 
Hooked
@rallygeek avatar
Polaris Grey Rally 200, Blue Marine Primavera ET3, Coral Red 50 Special
Joined: UTC
Posts: 384
Location: Melbourne
UTC quote
Looking good hjo.

I wouldn't worry that all the springs are not covered, that piece is held in place by some wire 'staples' into the springs themselves so you can position it for best cover.

That 'bar' I think is to stop springs spreading rather than keeping apart I think. I can't remember where it went but I think it would need to go in the middle of the main rider seat section.
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