Project 1974 Rally
sdjohn
Fri, 14 Oct 2022 16:18:02 +0000
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sdjohn
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Fri, 14 Oct 2022 16:18:02 +0000 quote
simple check hang a wrench from each flywheel magnet (just one wrench, move it around). 17mm i think, but you get the idea, it has to hold up the wrench or it's not strong enough.

Last edited by sdjohn on Fri, 14 Oct 2022 16:47:36 +0000; edited 1 time
chandlerman
Fri, 14 Oct 2022 16:45:40 +0000
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chandlerman
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Fri, 14 Oct 2022 16:45:40 +0000 quote
try hanging a 19mm wrench off the flywheel to check the magnetism.
OP
hjo
Fri, 14 Oct 2022 17:25:47 +0000
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hjo
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Fri, 14 Oct 2022 17:25:47 +0000 quote
chandlerman wrote:
try hanging a 19mm wrench off the flywheel to check the magnetism.
Just on the outside?
sdjohn
Fri, 14 Oct 2022 17:45:39 +0000
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sdjohn
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Fri, 14 Oct 2022 17:45:39 +0000 quote
on each magnet on the inside, like in this photo (thanks scooterwest):
SoCalGuy
Fri, 14 Oct 2022 22:08:56 +0000
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SoCalGuy
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Fri, 14 Oct 2022 22:08:56 +0000 quote
Check the gap between the cam and black pickup. Needs to be 0.25mm - 0.30mm.
Positive
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hjo
Sat, 15 Oct 2022 04:56:56 +0000
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hjo
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Sat, 15 Oct 2022 04:56:56 +0000 quote
Ah. I guess I need to pull the flywheel.

I hope it doesn't need to be replaced. Those are not easy to find. And I had it vapor blasted.

I guess I'll get the rest of the bike together.

I also need to rebuild the shifter box, or replace it. It shifts, but has a lot of play in the box itself, so it's a little squishy.

I guess that can be a project at any point, though.


Got the speedo cable to work. That was not easy. But it's very pretty. This was BGM version. Amazing to see it attach to the 50 year old brass thing.


This choke clip thing. How does it attach? It's asymmetrical, and there's a slot, and kind of a sheet metal fin thing close to it.


Some shots in almost done shape.







Last edited by hjo on Sat, 15 Oct 2022 05:41:42 +0000; edited 1 time
brok3nr0b0t
Sat, 15 Oct 2022 05:01:51 +0000
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brok3nr0b0t
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Sat, 15 Oct 2022 05:01:51 +0000 quote
You should be able to get the flywheel re-magnetized if that ends up being the issue. I know scooter west has a machine to do it but there might be someone closer to you that can do it also
OP
hjo
Sat, 15 Oct 2022 05:29:28 +0000
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hjo
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Sat, 15 Oct 2022 05:29:28 +0000 quote
brok3nr0b0t wrote:
You should be able to get the flywheel re-magnetized if that ends up being the issue. I know scooter west has a machine to do it but there might be someone closer to you that can do it also
I love Scooterwest. They rebuilt my stator. And most of the parts are from there.
Positive
Cdevillasante
Sat, 15 Oct 2022 15:37:10 +0000
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Cdevillasante
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Sat, 15 Oct 2022 15:37:10 +0000 quote
Looks great! that clip is a pain but it slides over the tube where the opening is, you just gotta finagle/ wrastle it. When it finds the right spot it clicks into place.
Choke Lever clip
https://www.scooterhelp.com/genmaintain/vespa.choke.cable.html
Rallygeek
Sun, 16 Oct 2022 10:15:22 +0000
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Rallygeek
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Sun, 16 Oct 2022 10:15:22 +0000 quote
hjo wrote:
Spark. No spark.

I disconnected the junction box, tried my spare Femsa. Tried the green/blue/red in forward and reverse order. Checked the ground on the Femsa (it goes to a bare frame post).

Nothing.

Not sure what's going on.

I had the stator checked and rewired by Robot. I'm sure that''s good.

I don't know if I put the stator the right way. But it only seems to fit one way.

And if it was the wrong way, it would probably spark, just at the wrong time, since it's all a circle.

Hm. I guess I could have damaged a wire pulling it through. The grommet was hard to get through. But seemed fine.
The bike is looking great.


Are you sure that the femsa boxes you have are all ok? A check would be to use a Ducati Cdi if you have one lying about and use the conversion method to test if it's the box. FEMSA's can be frustrating.

[url] http://www.vespa-klub.dk/Rally_CDI.HTM[/url] I think there were some recent posts on this forum about using the Ducati Cdi.
orwell84
Sun, 16 Oct 2022 17:50:48 +0000
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orwell84
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Sun, 16 Oct 2022 17:50:48 +0000 quote
Hang in there, you will get it. What a beauty.
OP
hjo
Sun, 16 Oct 2022 19:18:26 +0000
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hjo
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Sun, 16 Oct 2022 19:18:26 +0000 quote
Rallygeek wrote:
Are you sure that the femsa boxes you have are all ok? A check would be to use a Ducati Cdi if you have one lying about and use the conversion method to test if it's the box. FEMSA's can be frustrating.

[url] http://www.vespa-klub.dk/Rally_CDI.HTM [/url] I think there were some recent posts on this forum about using the Ducati Cdi.
Thanks. This looks complicated. But I'll try it. I have a Ducati cdi, and a third femsa box I can try.

It's possible that my others are dead.

Seems most likely since the stator was all checked and rewired.
OP
hjo
Sun, 16 Oct 2022 19:19:32 +0000
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hjo
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Sun, 16 Oct 2022 19:19:32 +0000 quote
Rallygeek wrote:
Are you sure that the femsa boxes you have are all ok? A check would be to use a Ducati Cdi if you have one lying about and use the conversion method to test if it's the box. FEMSA's can be frustrating.

[url] http://www.vespa-klub.dk/Rally_CDI.HTM [/url] I think there were some recent posts on this forum about using the Ducati Cdi.
Thanks. This looks complicated. But I'll try it. I have a Ducati cdi, and a third femsa box I can try.

It's possible that my others are dead.

Seems most likely since the stator was all checked and rewired.


Got this wired.


This worked well!

OP
hjo
Tue, 18 Oct 2022 01:04:13 +0000
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hjo
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Tue, 18 Oct 2022 01:04:13 +0000 quote
I spoke to Scooterwest, who rebuilt the flywheel, and they thought it was probably the gap with the cam/pickup.

That would be really the best case.
SoCalGuy
Tue, 18 Oct 2022 19:47:46 +0000
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SoCalGuy
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Tue, 18 Oct 2022 19:47:46 +0000 quote
SoCalGuy wrote:
Check the gap between the cam and black pickup. Needs to be 0.25mm - 0.30mm.
Ahem ... ^
OP
hjo
Tue, 18 Oct 2022 21:07:35 +0000
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hjo
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Tue, 18 Oct 2022 21:07:35 +0000 quote
SoCalGuy wrote:
Ahem ... ^
You called it!!
Ray8
Sun, 30 Oct 2022 00:32:41 +0000
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Ray8
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Sun, 30 Oct 2022 00:32:41 +0000 quote
Given your concours level restoration, have you considered sourcing mudguard reflectors?
Looks like you filled the holes...

But if so, I might have a NOS reflector hack.
$50 total, including Claus Studios gaskets.
OP
hjo
Sun, 30 Oct 2022 01:51:24 +0000
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hjo
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Sun, 30 Oct 2022 01:51:24 +0000 quote
Yes! Also the stripes.

The silver stripes are only made by Scooterwest, and they're ordering new ones.

The reflectors are impossible to find.

I did find these ones. They're the same reflectors, but don't have the aluminum frame.

I have to drill holes for them.

Is there a better fix?

I haven't touched the bike this week. Life things.







Birdsnest
Sun, 30 Oct 2022 02:36:22 +0000
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Birdsnest
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Sun, 30 Oct 2022 02:36:22 +0000 quote
Mark (Poi Dog) may have one.
I think he'd sell it…
Would get you half way there.
OP
hjo
Sun, 30 Oct 2022 02:56:07 +0000
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hjo
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Sun, 30 Oct 2022 02:56:07 +0000 quote
Birdsnest wrote:
Mark (Poi Dog) may have one.
I think he'd sell it…
Would get you half way there.
I have a friend who may have a set. I'll ask him.

This was very last step.
Ray8
Sun, 30 Oct 2022 17:22:27 +0000
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Ray8
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Sun, 30 Oct 2022 17:22:27 +0000 quote
hjo wrote:
I did find these ones. They're the same reflectors, but don't have the aluminum frame.

That's the very same hack.
Same number lens. Screw holes match.

I see now that the original frame is also wider than these




Frame covers the lens edge

OP
hjo
Sun, 30 Oct 2022 21:54:36 +0000
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hjo
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Sun, 30 Oct 2022 21:54:36 +0000 quote
Does the aluminum frame wrap around the whole thing? Or just cover the front?

I might be ok with the plastic reflectors. They are so close. The reflector even has the same part number.

It has a plastic back with posts that are melted around the bracket, but in the same place.

I thought I might be able to file those down and thread them with a die, and use a nylon nut.

It's funny. The rarest part of the Rally is little plastic reflectors that cost like 50 cents to make.



Ray8
Tue, 01 Nov 2022 16:18:35 +0000
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Ray8
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Tue, 01 Nov 2022 16:18:35 +0000 quote
Those plastic nubs dremel off in seconds. Bracket lifts right off.

I drilled plastic epoxy wells in a drill press and used #4 screws.
Considered using zinc came (used to wrap stained glass), rolling one side of the U flat and wrapping it. Something like this:

https://www.amazon.com/Zinc-6ft-Came-Into-Pieces/dp/B00LLVORLU/ref=sr_1_16?crid=7XF446GKDEKM&keywords=5%2F16+round+u+came&qid=1667158377&sprefix=5%2F16+round+u+came%2Caps%2C264&sr=8-16

But the plastic is good enough for my hole covering project.

And yeah, it is funny. Saw a pair on FB for $200+ that sold right away





oopsclunkthud
Tue, 01 Nov 2022 19:54:34 +0000
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oopsclunkthud
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Tue, 01 Nov 2022 19:54:34 +0000 quote
if you don't have holes in the fender I'd use 3M double sided tape.
Positive
sdjohn
Tue, 01 Nov 2022 20:26:01 +0000
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sdjohn
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Tue, 01 Nov 2022 20:26:01 +0000 quote
there's always shoe goo....
Christopher_55934
Wed, 02 Nov 2022 11:15:08 +0000
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Christopher_55934
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Wed, 02 Nov 2022 11:15:08 +0000 quote
Ray8 wrote:
Those plastic nubs dremel off in seconds. Bracket lifts right off.

I drilled plastic epoxy wells in a drill press and used #4 screws.
Considered using zinc came (used to wrap stained glass), rolling one side of the U flat and wrapping it. Something like this:

https://www.amazon.com/Zinc-6ft-Came-Into-Pieces/dp/B00LLVORLU/ref=sr_1_16?crid=7XF446GKDEKM&keywords=5%2F16+round+u+came&qid=1667158377&sprefix=5%2F16+round+u+came%2Caps%2C264&sr=8-16

But the plastic is good enough for my hole covering project.

And yeah, it is funny. Saw a pair on FB for $200+ that sold right away
If you don't use some odd metric size like a 4.5mm it's considered a bog fix.
OP
hjo
Fri, 04 Nov 2022 01:37:13 +0000
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hjo
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Fri, 04 Nov 2022 01:37:13 +0000 quote
Life has been a little chaotic, and left this.

The wires appear to be working. Attached the switches and the tail and brake lights work.

The LEDs are not very bright!








The material on this doesn't tap. It's not dense enough. Stripped out. Can I epoxy or super glue this maybe?

GeekLion
Fri, 04 Nov 2022 21:59:24 +0000
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GeekLion
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Fri, 04 Nov 2022 21:59:24 +0000 quote
I did 2 of those levers to fit the brake switch post. One of them tapped ok, the other barely held the threads; same as you. So this is one rare instance where I would use...JBWeld. Pack some in, thread it and go. Held up fine for the one of mine.
oopsclunkthud
Fri, 04 Nov 2022 22:10:51 +0000
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oopsclunkthud
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Fri, 04 Nov 2022 22:10:51 +0000 quote
Where did you get the reflectors from? think I may need to add them back on mine.
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hjo
Fri, 04 Nov 2022 22:50:48 +0000
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hjo
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Fri, 04 Nov 2022 22:50:48 +0000 quote
oopsclunkthud wrote:
Where did you get the reflectors from? think I may need to add them back on mine.
Treatland, if I remember. They're wheel reflectors from Italian mopeds.
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hjo
Fri, 04 Nov 2022 22:53:42 +0000
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hjo
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Fri, 04 Nov 2022 22:53:42 +0000 quote
I got some of this stuff. There store also had JB Weld, but I think this might be less messy.

The tap just stripped the metal right out. But it's super soft aluminum. It was very easy to drill.

The post is such a hack thing. It's just a screw with a piece of tubing over it.



OP
hjo
Sat, 05 Nov 2022 07:49:42 +0000
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hjo
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Sat, 05 Nov 2022 07:49:42 +0000 quote
The harness appears to work.

Though the LED flasher doesn't. It emits a loud tone, and the lights stay on.

In the reverse position with the wires, the lights flash once, and stop.

I'm not sure how the electrical works. There are three positions for the lights. One turns on the tail light. The brake works in all three. And the high beam indicator does too, so I might have put a wire in the wrong place on the switch.


Switches. Working even.

The horn isn't. But I think it might need to be adjusted.


But the lights are connected.


Everything but the speedo wire, which was upstairs.


The high beam indicator is red, for some reason. It's so funny how this works. It's a bulb that lights up the whole inside of the headset.


ok. the switch just pushed the post out. This did not work. But the epoxy takes a day to set, so hopefully it's better tomorrow.


The switch cover is the only thing with original patina.

Christopher_55934
Sat, 05 Nov 2022 14:50:30 +0000
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Christopher_55934
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Sat, 05 Nov 2022 14:50:30 +0000 quote
hjo wrote:
Life has been a little chaotic, and left this.

The wires appear to be working. Attached the switches and the tail and brake lights work.

The LEDs are not very bright!
Is there enough material to insert a helicoil or thread repair kit? I've done that previously in aluminum when I had this issue.
OP
hjo
Sat, 05 Nov 2022 18:12:31 +0000
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hjo
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Sat, 05 Nov 2022 18:12:31 +0000 quote
Christopher_55934 wrote:
Is there enough material to insert a helicoil or thread repair kit? I've done that previously in aluminum when I had this issue.
Not for this size screw.

My tap set didn't seem to work, partly because the taper before it threads is too deep, but also the material is so soft, when it got to the threads, it just stripped right away.

It might work better to make like a dowel in a lathe that is the same shape.

This is such a hacky thing. Just a screw tapped in.
Ray8
Sun, 06 Nov 2022 00:40:16 +0000
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Ray8
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Sun, 06 Nov 2022 00:40:16 +0000 quote
Pretty sure you'd have better luck with this setup.

With epoxy thread repair and some under the plate it'll outlast us all.


Works

OP
hjo
Sun, 06 Nov 2022 02:38:18 +0000
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: Fri, 31 Jul 2009 05:05:38 +0000
Posts: 1722
Location: San Francisco, CA
 
OP
hjo
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: Fri, 31 Jul 2009 05:05:38 +0000
Posts: 1722
Location: San Francisco, CA
Sun, 06 Nov 2022 02:38:18 +0000 quote
All the lights work.

I must have wired the switch wrong.

The taillight comes on in one position, but the headlight is on when the key is on.

I think the headlight should only come on when the taillight is on. But I am not sure what the three switch positions are.






0 miles. I hope this isn't a problem registering it.

OP
hjo
Sun, 06 Nov 2022 07:07:01 +0000
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: Fri, 31 Jul 2009 05:05:38 +0000
Posts: 1722
Location: San Francisco, CA
 
OP
hjo
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: Fri, 31 Jul 2009 05:05:38 +0000
Posts: 1722
Location: San Francisco, CA
Sun, 06 Nov 2022 07:07:01 +0000 quote
This thing is such an ordeal. It will eventually get there.

Something seemed strange about my back wheel, and it looks like it is warped, somehow.

It's an original Piaggio rim, but a vintage one.

Also, I tried to bold down the exhaust, and the caged nut is stripped.

It's like every single thing. ::
chandlerman
Sun, 06 Nov 2022 11:04:54 +0000
Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: Thu, 16 Jun 2011 14:59:35 +0000
Posts: 7216
Location: Nashville
 
chandlerman
Lucky
76 Sprint V, 63 GL, 62 VBB, 05 Stella, 66 Smallstate, 08 Stella (for now)
Joined: Thu, 16 Jun 2011 14:59:35 +0000
Posts: 7216
Location: Nashville
Sun, 06 Nov 2022 11:04:54 +0000 quote
It could be worse. It could be the axle.

Frustrating, I know, but comes with the territory.

Replacing the caged nut isn't a big deal. It's a great concept when it works, but that's a maddeningly low percentage of the time.
Jack221
Sun, 06 Nov 2022 11:59:54 +0000
Jet Eye Master
PX221 MHR, O tuned PX200, PX181 Quattrini and some motorbikes
Joined: Thu, 15 Jun 2017 05:16:54 +0000
Posts: 3661
Location: London UK
 
Jack221
Jet Eye Master
PX221 MHR, O tuned PX200, PX181 Quattrini and some motorbikes
Joined: Thu, 15 Jun 2017 05:16:54 +0000
Posts: 3661
Location: London UK
Sun, 06 Nov 2022 11:59:54 +0000 quote
hjo wrote:
This thing is such an ordeal. It will eventually get there.

Something seemed strange about my back wheel, and it looks like it is warped, somehow.

It's an original Piaggio rim, but a vintage one.

Also, I tried to bold down the exhaust, and the caged nut is stripped.

It's like every single thing. ::

Not much to worry about on a stock build. However, that clicking sounds like gear misalignment. If it is, extra gaskets under the selector box usually fix it.
OP
hjo
Sun, 06 Nov 2022 18:43:38 +0000
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: Fri, 31 Jul 2009 05:05:38 +0000
Posts: 1722
Location: San Francisco, CA
 
OP
hjo
Molto Verboso
Scattered remnants of (two!) 1974 Rallys
Joined: Fri, 31 Jul 2009 05:05:38 +0000
Posts: 1722
Location: San Francisco, CA
Sun, 06 Nov 2022 18:43:38 +0000 quote
Jack221 wrote:
Not much to worry about on a stock build. However, that clicking sounds like gear misalignment. If it is, extra gaskets under the selector box usually fix it.
I think it's the selector box. When I shift, the selector gear has a lot of play. It moves up and down where the cables attach
  DoubleGood Design  
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