Modern Vespa

This 71 Rally 180 is vexing me. The motor is good, (I'll do the seals and rebuild the clutch), I have a new front mudguard, new center stand, new seat.
But there are holes in the leg shield from crash bars and also holes in the floor, (10 of them!) I'm going to have the 2 legshield holes welded up, and primed for $200, but the 10 (smaller) floor holes, I'm not sure how to proceed. Had planned to plug them with grommets, but frankly that looks pretty tacky. Welding them up will require removal, and reinstalling of all the floor rails (which I can do) and probably another $200 for my welder buddy.
Paid $2300 for the scooter and it's not rusty, just ugly!

You can fill the holes on the floor with JB Weld, sand flush and use touch up paint. Just tape one side of the hole and fill from the other side. That would be pretty easy. Just need to clean the holes first. Welding them up would be the best though.

Decorative stainless bolts? any good as an idea?

Pop the floor rails and weld them up.

It's a rally 180… so it's worth doing right.
Reinstalling the floor rails isn't bad with the floor rail tool, and I bet we can find somebody to loan you one if you don't have one in your toolbox.

What happened to the floor, did it used to run a sidecar?

No sidecar, those crash bars were popular on the Rally 180's, for some reason. I bet there were also foot pegs or something too, before I got the scooter.
I do have the floor rail rivet tool, and I think I'll go ahead and have the holes welded up.

good call. Anything worth doing it worth doing right.

My '71 Rally 180 has a metric shit ton of various holes in the legsheild, and a couple on the floor as well as various mounting holes for tail lights and license plates. The one that perplexes me the most is a hole about a 1/2" in diameter on the left floorboard. perfectly circle neat hole, so done on purpose. Just a mystery.

But I definitely know the pain of bonus holes and YES it's worth it to do em up right on a Rally 180!!!

Holes are welded up. I'm doing a bit of touch up rattle can painting.

Horn is giving me trouble. I know it works, I can get to make some noise when connected to the 6V battery and grounded. But when it's on the scoot, I get nothin.
The wiring diagram from scooterhelp, doesn't match the wire colors on mine. But the wires do look original.
1, tested the horn, it works.
2, kill switch works, so I have good ground?
3, swapped out the switch, no help.
Tonight I connected a ground directly to the horn and started the scooter, and the horn worked. (Pretty wimpy, but it made some noise) should I assume that the switch is not properly grounding the horn?