Thu Nov 25, 2021 7:20 am

Molto Verboso
Joined: 03 Nov 2011
Posts: 1403
Location: Racing Capital of the World
 
Molto Verboso
Joined: 03 Nov 2011
Posts: 1403
Location: Racing Capital of the World
Thu Nov 25, 2021 7:20 am linkquote
Was sent a set of cases from a friend that I have known for the better part of two decades.

These cases were modified in the early 2000's for a DR177; 2-port to 3-port conversion.

No good reason to use that cylinder now days when we have BGM177 and VMC 177 in the market with modern performance and quality at fantastic prices.

There were some things done originally I don't understand. If you you TIG weld and machine the cases for the 3rd port, why not TIG weld the void and machine the gasket surface? Why not TIG weld the sides of the cases?

so I have updated this case for a modern cylinder: BGM177. Void and sides TIG welded, gasket surfaces milled, ports matched. I still have to deal with the inlet, but I will get to that later.

Before and after photos for your pleasure.

Happy Thanksgiving friends. Appreciate all of you. πŸ‡ΊπŸ‡ΈπŸβ€οΈ


2-port cases that have been modified to 3-port in the early 2000's.


Void was filled with some type of epoxy I reckon.


BGM177 gasket layer over gasket surface.


Original transfer work for the DR177


I removed all the fill here. Deep void.


hieroglyphic.


Added aluminum here; otherwise you will break through the side of the case.


Added aluminum here; otherwise you will break through the case and run out of cylinder gasket surface.


Case gasket surface and cylinder gasket surface milled true. Ports are matched to the cylinder.


BGM177 cylinder gasket laid onto the case-matched.


This area has a previous repair. . . And really not that great. Entire thing should have been removed, TIG welded, and machined for the m6 thread. I had to mill this surface to get this to bolt onto the table true.


Someone is about to get some quality equipment back.

Thu Nov 25, 2021 8:03 am

Ossessionato
Joined: 22 Oct 2011
Posts: 4660
Location: Tega Cay, SC
 
Ossessionato
Joined: 22 Oct 2011
Posts: 4660
Location: Tega Cay, SC
Thu Nov 25, 2021 8:03 am linkquote
Excellent work as always. Thanks for posting.
Thu Nov 25, 2021 8:28 am

Molto Verboso
Vespa
Joined: 19 Jun 2007
Posts: 1372
Location: California
 
Molto Verboso
Vespa
Joined: 19 Jun 2007
Posts: 1372
Location: California
Thu Nov 25, 2021 8:28 am linkquote
outstanding refresh especially the tig work.
Thu Nov 25, 2021 8:49 am

Ossessionato
62 VBB1T Round Tail W/ leaner sidecar
Joined: 26 Jan 2019
Posts: 2639
Location: california
 
Ossessionato
62 VBB1T Round Tail W/ leaner sidecar
Joined: 26 Jan 2019
Posts: 2639
Location: california
Thu Nov 25, 2021 8:49 am linkquote
Nice job with the welding Jon.
Those thin areas and inside holes can be tough.
Very clean.
Thu Nov 25, 2021 10:01 am

Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 5375
Location: San Diego, CA
 
Veni, Vidi, Posti
'15 GTS300, '86 PX125EFL, '66 VBB, '04 Ninja 250
Joined: 04 Apr 2013
Posts: 5375
Location: San Diego, CA
Thu Nov 25, 2021 10:01 am linkquote
Your hieroglyphic looks like HRS = Hot Rod Al Scooters
Fri Nov 26, 2021 10:13 am

Member
'63 GL, '74 PV
Joined: 11 Oct 2021
Posts: 10
Location: Chicago
 
Member
'63 GL, '74 PV
Joined: 11 Oct 2021
Posts: 10
Location: Chicago
Fri Nov 26, 2021 10:13 am linkquote
This is from my '63 GL (I think the entire run of GLs that year were sold in Chicago). The woe that has befallen the casing (by me and so many others) is only matched by the woe that has befallen the frame, but all be made right, as these are metal bikes.
Mon Nov 29, 2021 3:41 am

Ossessionato
2 matching N.Z. '69 VBC Super, 177cc Racer, VespaCross Bodge, Puch SRA150, Piaggio Zip 100! & others
Joined: 26 May 2013
Posts: 4189
Location: That bushfire place
 
Ossessionato
2 matching N.Z. '69 VBC Super, 177cc Racer, VespaCross Bodge, Puch SRA150, Piaggio Zip 100! & others
Joined: 26 May 2013
Posts: 4189
Location: That bushfire place
Mon Nov 29, 2021 3:41 am linkquote
I had a port added to Speedy many moons ago, dunno the process they used, but don't think TIG was as accessible/cheap back then.
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