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parallelogramerist
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Since the scooter will be DC powered the original AC horn won't work for my application anymore. I ended up using a 12DC PK horn and the outer horn shell cover from the VB1. It took a bit of grinding and trimming on the PK horn to get it the right dimensions so that i could simply set the VB1 shell directly over the top of it.
12VDC PK horn
12VDC PK horn
where i cut part of the PK's horn shell off of the main body
where i cut part of the PK's horn shell off of the main body
VB1's AC horn
VB1's AC horn
Forum member supplied image with no explanatory text
I also had to open up the inner diameter of the horncasting about 1/8" so that the PK horn would fit.
I also had to open up the inner diameter of the horncasting about 1/8" so that the PK horn would fit.
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Forum member supplied image with no explanatory text
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parallelogramerist
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I also installed clutch and gear cables today (no throttle or choke cable just yet). I have a long roll of cable that i bought from Motion Pro. MP also sells the matching metal ferrals.
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Forum member supplied image with no explanatory text
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parallelogramerist
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I got 99% of the wiring completed today. I powered up the harness so that i could test everything. Everything works great when it's hooked up to a stable 12VDC power source. I'm really curious just how well everything will work with just the capacitor.

I will still have to aim and then somehow mount and anchor the LED light, but that will have to be done once the scooter is up and running.
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Forum member supplied image with no explanatory text
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Nedminder
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Quote:
How crazy?...well, let's just say that if anyone rear ends me, they will have done it on purpose.
Hahahaha.

Scoot is looking so
Good.
Extra mile on brakes, lighting, front end fork tube, are gonna make it sucha cool scoot to ride.
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parallelogramerist
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charlieman22 wrote:
Hahahaha.

Scoot is looking so
Good.
Extra mile on brakes, lighting, front end fork tube, are gonna make it sucha cool scoot to ride.
I'm definitely in the home stretch now. Maybe i can get it up an running by next weekend? I'm also going to have to figure out how to get the scooter off the saw horses. All the individual bits and pieces were lightweight enough when assembling them to the frame. I wonder just which part (or parts) will be the straw that breaks the camel's back when it comes time to pick it up.
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Ossessionato
2007 Stella 225
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whodatschrome wrote:
I'm definitely in the home stretch now. Maybe i can get it up an running by next weekend? I'm also going to have to figure out how to get the scooter off the saw horses. All the individual bits and pieces were lightweight enough when assembling them to the frame. I wonder just which part (or parts) will be the straw that breaks the camel's back when it comes time to pick it up.
Engine hoist to lift it up?
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parallelogramerist
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Christopher_55934 wrote:
Engine hoist to lift it up?
I might just have to use my middle age man strength and just hump it up bare handed, but it might be until next week until i do that. The reason being is that i got some food poisoning last saturday and i still feel pretty darn lousy this saturday. I don't want a mishap and be forced to do a wardrobe change midday...

*Pro tip, don't eat the eggs chorizo at the Best Western in Tucson, Arizona
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parallelogramerist
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I did a little bit of aesthetic work today on the LED headlight bezel. I sanded off all the black anodizing and then polished it up. I started out with 220 grit on the DA sander, then to 320, then a final quick 400 grit. Then used a bidding wheel to make it shiny. I didn't want absolute perfection whatsoever, just something that would kinda blend in with some of the other aged shiny bits that are currently on the scooter. I think the polished bezel looks MUCH better on the scooter than the anodized black.
after sanding all the black anodizing off the bezel with 400 grit
after sanding all the black anodizing off the bezel with 400 grit
what the bezel looks like after polishing it.
what the bezel looks like after polishing it.
glamour shot of the bezel
glamour shot of the bezel
second glamour shot
second glamour shot
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bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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Dig the polished bezel. Get what you're trying to do with the amber light, but if you were taking a vote, I think I'd go with a clear lens. Really nice work.
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SoCalGuy wrote:
Dig the polished bezel. Get what you're trying to do with the amber light, but if you were taking a vote, I think I'd go with a clear lens. Really nice work.
I have a heart for amber colored lenses on really really old motos...but looking at my pics a third time, you just might be right about a clear lens looking better on this particular project. The other benefit of switching back to a clear lens is that i'll get a ton more lumins back that the amber lens is currently sapping. I'll look into that option. Thank you for the input!

I think i would need more yellow or gold accents on the scooter so that the amber lens wouldn't be such a prominent feature. A gold colored SIP brake caliper, gold master cylinder reservoir for the rear disc brake, gold brake banjo bolts and fittings, and something gold colored in the tail area could work, but then it might throw the whole rusty look thing out the window.
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Molto Verboso
'07 GTS250, '07 LX150, '81 P200E, '78 P200E, '74 VBC1, '64 V90 and 3 Ciaos
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whodatschrome wrote:
I might just have to use my middle age man strength and just hump it up bare handed, but it might be until next week until i do that. The reason being is that i got some food poisoning last saturday and i still feel pretty darn lousy this saturday. I don't want a mishap and be forced to do a wardrobe change midday...

*Pro tip, don't eat the eggs chorizo at the Best Western in Tucson, Arizona
Dude, ur in my hood? There is way better breakfast to be had in this burg.
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parallelogramerist
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az_slynch wrote:
Dude, ur in my hood? There is way better breakfast to be had in this burg.
I was very briefly in Tucon. I was on my way back from the week long Sonora Rally navigation race that was held down in the Hermosillo, Mexico area. I was with 3 other guys in a van and i was one their time, not mine. There was zero time for any sort of side excursions...except for eating a plate of eggs uneasy.
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parallelogramerist
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SoCalGuy wrote:
Dig the polished bezel. Get what you're trying to do with the amber light, but if you were taking a vote, I think I'd go with a clear lens. Really nice work.
Speaking of voting, the only poll that was needed was to pull the amber lens from the bezel and replace it with a clear. I think it looks much better now. Thank you for the aesthetic advice!
Forum member supplied image with no explanatory text
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Just a quick note to say... this thread is always so entertaining to catch up on!!!
Build of the year thread. Truly.
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bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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bodgemaster
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whodatschrome wrote:
I think it looks much better now. Thank you for the aesthetic advice!
Most welcome. Clear is much cleaner & goes better with that beautiful suspension.
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Nedminder
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Birdsnest wrote:
Just a quick note to say... this thread is always so entertaining to catch up on!!!
Build of the year thread. Truly.
Second that notion.

Whodat- what are the big jobs still left? Looks almost ready to ride.
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Ossessionato
1958 Allstate 177VMC, 1962 Allstate, Yamaha Vino 70cc
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Ossessionato
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UTC quote
whodatschrome wrote:
I have a heart for amber colored lenses on really really old motos...but looking at my pics a third time, you just might be right about a clear lens looking better on this particular project. The other benefit of switching back to a clear lens is that i'll get a ton more lumins back that the amber lens is currently sapping. I'll look into that option. Thank you for the input!

I think i would need more yellow or gold accents on the scooter so that the amber lens wouldn't be such a prominent feature. A gold colored SIP brake caliper, gold master cylinder reservoir for the rear disc brake, gold brake banjo bolts and fittings, and something gold colored in the tail area could work, but then it might throw the whole rusty look thing out the window.
Same with the yellow lights on oldies over here, but it looks better with the clear bezel on yours.
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parallelogramerist
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charlieman22 wrote:
Second that notion.

Whodat- what are the big jobs still left? Looks almost ready to ride.
Well, right before i tried installing that throttle cable that was binding, i thought i didn't have any big jobs left. So yeah, the last 10% takes 90% of the time!

I'm hoping i can get the scooter back on its feet by friday afternoon? Maybe not running just yet, but i'm hoping for 99% assembled. I think i just need to install the aluminum floorboard structure and centerstand, jet the T5 24/24 carb, and install the fuel tank.

I did get both the front and rear hydro brakes bleed. I did a test and both front and rear brake pressure switches do work.

I painted the new fuel tank with a grey epoxy primer last week. I rattle canned a bronze hammer type paint over the top of the primer. It doesn't match the current finish on the scooter, but it looks 100% better than just a grey primer color. The textured hammer paint does give it sort of a pitted rust look from afar though. I think once the saddle seat is installed the tank will blend in well enough. The bonus was that i already had the hammer paint in my shop.

I also wire wheeled the inside of the rims, then dunked them in Ospho, then brushed them with primer. I'm trying to let the primer harden up a few more day before i go installing tires and tubes.
A VERY rusted out tank that was out of my other VB1.
A VERY rusted out tank that was out of my other VB1.
i purposefully spray the rattle can hammer paint in a way to create a mottled look. I didn't want an even look to the texture.
i purposefully spray the rattle can hammer paint in a way to create a mottled look. I didn't want an even look to the texture.
rusty rims
rusty rims
this really rusty rim can be used for my spare tire
this really rusty rim can be used for my spare tire
throttle and choke cables are now installed
throttle and choke cables are now installed
Forum member supplied image with no explanatory text
lock cylinder is now installed. The key fob is actually the dewclaw off of my late pot bellied pig (RIP Bentley).
lock cylinder is now installed. The key fob is actually the dewclaw off of my late pot bellied pig (RIP Bentley).
⚠️ Last edited by whodatschrome on UTC; edited 1 time
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Throttle cable now sorted! The throttle tube doesn't snap back closed
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Nedminder
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I don't know where to start.
The tank paint is brilliant.
The dew claw is… unexpected.
Tru love.
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bodgemaster
63 GL, 76 Super (x2), 74 Primavera (x2), 79 P200, 06 Fly 150
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Bentley reminds me of the old joke about the pig that was too good to eat all at once.
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charlieman22 wrote:
The dew claw is… unexpected.
Tru love.
lucky pig's foot
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parallelogramerist
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i'm getting a bit closer...
I knew that a P series kickstart lever was going to foul out against the floorboard. I had planned on bending the lever...but then i quickly checked my memory banks and an alert popped up. I did a quick search in my kickstarter collection and found a likely donor. I fitted it up, and wouldn't you know it?...the lever was already bent to the exact position that i needed to be in! It happened to be bent down about 1/2" and out away from the engine an 1".
the straight kickstart lever makes contact with the floorboard
the straight kickstart lever makes contact with the floorboard
a straight lever also just barely kisses the cowl.
a straight lever also just barely kisses the cowl.
the bent lever gives me perfect clearance to the floorboard
the bent lever gives me perfect clearance to the floorboard
the bent lever also give me perfect space from the cowl
the bent lever also give me perfect space from the cowl
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parallelogramerist
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I got all the cables and the harness tidied in the frame tunnel, bolted up the aluminum floor plate, then *TRIED to install the Sito+.


*long story short, i tried heating up the neck of the Sito (where the O ring seal is located) with a propane torch, and then, BOOM! Apparently something got ignited and shot an exploding flame burst into my face. It burned off some of my right side eyebrows, half my right side eye lashes, and burned some of my eyeball itself! Bummer was that i had to take a quick trip to the ER, instead of working on the scooter for the rest of the day. My ball should heal up fine, but it does hurt quite i bit. The Doc gave me a couple "special" numbing eye drop that took 100% of the pain away. He did say that unfortunately that they can't give the rest of the eye drop bottle away. Once he was done with working on my eye, he left the room and left the eye drop bottle on the table right next me. I was confident enough that he did that on purpose, so i didn't feel wrong about rescuing that bottle from its inevitable short lived life in the hazmat garbage can. It's a good thing too, because i took another drop of it on my way home...and perhaps one more drop after i got hole so that i could finish installing that Sito+!
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Forum member supplied image with no explanatory text
Forum member supplied image with no explanatory text
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Ossessionato
79 P200E (Ruby), 62 Allstate (B-62)
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Damn! My buddy Chris ALWAYS calls me on not wearing eye protection. I'm getting better though with stories like this!
⚠️ Last edited by qascooter on UTC; edited 1 time
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qascooter wrote:
Damn! My buddy Chris ALWAYS callse on not.wearing eye protection. I'm getting better though with stories like this!
I usually do wear eye protection. But i literally and figuratively didn't see any sort of possibility for a small fireball explosion to happen. Hindsight, what caused it was that i shot a couple small short blasts of silicon spray on the exhaust O ring. It was at least a couple minutes later before i introduced the open flame. It was just something i didn't foresee.
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Nedminder
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UTC quote
Damn.
Scary.
Need to buy myself some better safety glasses.
Hope you heal up quick.

Did you seriously come back and put the exhaust on?
Jeez.

What are those cable holders that align them so nice in a row like that?
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Molto Verboso
'07 GTS250, '07 LX150, '81 P200E, '78 P200E, '74 VBC1, '64 V90 and 3 Ciaos
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Molto Verboso
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UTC quote
charlieman22 wrote:
Damn.
Scary.
Need to buy myself some better safety glasses.
Hope you heal up quick.

Did you seriously come back and put the exhaust on?
Jeez.

What are those cable holders that align them so nice in a row like that?
They look a bit like aftermarket plug wire retainers for a V8 from where I'm sitting.

Whodats, yikes! You're too close to riding it to blind yourself! Take care man!
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External inline image provided by member with no explanatory text

Yeeesh.... glad all is (or will be) Ok!
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Good grief man! Protect yer balls, we can't replace them, yet.
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parallelogramerist
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charlieman22 wrote:
Did you seriously come back and put the exhaust on?
Jeez.

What are those cable holders that align them so nice in a row like that?
nooo...well maybe some...yes. Yes i did. I didn't want to got to bed completely defeated. I can only thank the magic eye drops that i got from the hospital. They make the eye go numb in about 30 seconds, and one drop will last me about 30 minutes. The drops are pretty amazing. When the doctor applied them in my eye, he missed my ball and it dribbled into my already cascading tear flow that i had going on, then dribbled down to the right side corner of my mouth. Pretty soon my lip and tongue went numb.

Those are just zip-ties. Zoom in if you can. They're a poor man's sparkplug wire organizer. That little trick looks pretty trick and works really well.
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Ossessionato
79 P200E (Ruby), 62 Allstate (B-62)
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whodatschrome wrote:
Those are just zip-ties. Zoom in if you can. They're a poor man's sparkplug wire organizer. That little trick looks pretty trick and works really well.
I like it - very trick! Clap emoticon Clap emoticon
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Nedminder
62 VBB1T Round Tail W/ leaner sidecar
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Somewhere in a Pacific North West emergency room:
Dr: Nurse, have you seen the droplet bottle?! I left it in the patients room.
Nurse: No Dr., which bottle?
Dr: The one with an eyelet dropper containing Heroin
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charlieman22 wrote:
Somewhere in a Pacific North West emergency room:
Dr: Nurse, have you seen the droplet bottle?! I left it in the patients room.
Nurse: No Dr., which bottle?
Dr: The one with an eyelet dropper containing Heroin
lol

Now y'all got me wondering what the heck exactly inside that little dropper bottle. I was going to help a friend do some welding today, but i told him about my little fireball incident and how i have a new bottle of eye drops. He jokingly asked if it was liquid cocaine. Now you guys got me worried! I did quite using them last night right before i went to bed. Though the eye is still painful, it's now easily manageable. I can now open my eye about 25% of the time so all is good. I did quit the eye drops cold turkey last night.
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parallelogramerist
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I got a bunch of stuff done on the scooter today...
-tires and rusty wheels mounted.
-side cowls adjusted and installed.
-license plate bracket installed.
-P200 helmet (luggage) hook installed.
-rear brake reservoir attached to a mounting point.
There's lots of P200 bits on and in the scooter, so why not add a corroded P series luggage hook?
There's lots of P200 bits on and in the scooter, so why not add a corroded P series luggage hook?
the brake reservoir got mounted to the spare tire carrier.
the brake reservoir got mounted to the spare tire carrier.
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parallelogramerist
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And some pics with the cowls finally attached! I'm hoping to get more of the smaller details finished tomorrow.
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Ossessionato
2007 Stella 225
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Ossessionato
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2007 Stella 225
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UTC quote
whodatschrome wrote:
I got a bunch of stuff done on the scooter today...
-tires and rusty wheels mounted.
-side cowls adjusted and installed.
-license plate bracket installed.
-P200 helmet (luggage) hook installed.
-rear brake reservoir attached to a mounting point.
Really like the steam punk vibe this thing is starting to give off.

That plastic brake reservoir setup just won't do. Need to find some metal preferable aluminum. Maybe some SS braiding over plastic hose?

Don't tell her but she has a wide butt with those fenders mounted.
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Nedminder
62 VBB1T Round Tail W/ leaner sidecar
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*Spectacular wide butt, in my humble opinion.
How will you possibly opt to ride another after this is up and running?
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***Cues up Sit Mix Alot
Turns it up to 11***
⚠️ Last edited by Birdsnest on UTC; edited 1 time
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Sergeant at Arms
Weird 80's Vespas & Cool Vintage Lambrettas
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Location: The state of insanity, SoCal
 
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absolutely stunning work John.
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