Take a Seat

www.scooterlabs.net

Today I started work on the seat

.. and got a cylinder base packer CNC routed

And started the maths of port timing, squish and compression. 

Here's the kicker

Cases together. 

WHO IS THE MAN WHO WOULD RISK HIS NECK FOR ANOTHER MAN?

....... SHAFT

Drive-shaft

Secret Seat

Tonight I started the customisation of the tank.

sacrificed a Lambretta tank for the tap thread. 

At the 11th hour I realised that moving the filler forward would make it impossible to do up the nut on a vespa fuel tap from the inside. 

Special mention to Larsn Harsn for the lateral thinking. 

Decisions

This is where you get the idea of how I use blogs to gather info and remember my reasoning.

Options based on a bit of research
EDITS  - MAy 28 2015 in green

case - VS5

GEARBOX - stock gs150 - no choice

PRIMARY AND CLUTCH -

1.  Stock - have already. Stock 22 tooth vs3 clutch /stock cush gear 67 tooth
2.  Slight upgear - (in case I do get a little more power out of the motor) - need a VS5 clutch and adapt a p200e 23 tooth clutch cog. 
3. fancy base plate (DRT) made for a p200e clutch. This is 172 dollars but seems to be cheaper than finding a VS5 clutch. * needs more research - I WENT WITH THIS OPTION. It seems the German translations have created confusion, and the 23 tooth p200e clutch gear is too large a diameter to fit. I HAVE ORDERED A drt clutch cog so hopefully that will work. 
4. all out upgear kit requiring new clutches and rebuilding cush gear. not really necessary at his stage BUT worth considering the possible need in the future for some serious upgearing. 

TOP END

1. Remade 57.8 from scooter centre.  matched to a Grand Sport piston. 
2. As above with mild porting and enhanced port timings.... THIS ONE
3. crazy-ass Quattrini kit. no chance at this stage. 

CRANK

1. already bought a new standard crank. Most likely to use this due to time and money constraints. Yes I used this option.
2. A very tempting longstroke kingwave hand made crank - 400 euro

CARB - this is the hard part

1. stock - requires finding a carb (250-350 dollars) and praying it is half decent. Buying a choke mechanism, inlet manifold and airbox. Unlikely at this stage. 
2. put a 24mm phbl on a custom rear-facing 90 degree manifold. these manifolds are out of stock at SIP so here's hoping. STILL THE HOT FAVOURITE
3. The option I haven't thought of yet

EXHAUST

1. I bought a custom expansion chamber from a dude in the USA. I'll need to inspect it further and start planning appropriate port timing. This supports the more modern carb option. 
2. Stock/traditional sport is an option if the chamber robs the scooter of torque, especially if upgear option 2 or 3 are used. 

IGNITION

Vespatronic. only choice.

THis will require a special loom/harness which I already have. I may pop a non-used battery in there for touring use. 

I believe I also need a different key switch. No big deal as I don't have an original one anyway. 

RESEARCH

FLOORED

New tunnel patch is in and smooth. 

Floor is fitted snugly and spot welded in, awaiting butt welds where it meets the legshields. 

Started work on the rear skirt.

all's weld that ends weld

First patch welded in. Better and stronger than the original. 

Side tunnel patch this weeks and a few little one... then the floor goes in.

OK OK the engine.

Time to admit there still is no motor.
I have a case coming from up north, and some peripherals coming from the East coast.
This is good (he says) because it gives me more time to plan how to squeeze every possible tenth of a horsepower from a stock gs150 lump.

UMM... so I stopped typing this to find a pic of an engine when the postman popped in with this....

GAME ON

Patchwork and engine (what engine?)

Miraculously, the rust damage to this body is is specific spots that are relatively easy to patch. 

Even more miraculous is the fact that all the damage is on the outside and even under this yukky bit the steel on the next level is in really good shape.  TFFT.

This patch was made starting with a hand roller before cutting to shape. Next the shape was customised at the edges top follow the pressing shape of the original GS. Will be butt welded in this week. 

The inside of the tunnel is also in good nick. 100% steel in the centre. The left hand radius edge will be replaced before the legshield shape is prepared for the new floor installation.