My Mostly Suzuki AZ50 Based build... ... Is now a Let's II

[Raizer]

Thanks!

Started trying to figure out where to put my feet today, I think the original mesh floor idea I had isn't going to work as with the frame design the floor either ends up sitting way to high, or just ends up too short for my feet to fit.

Soo looking around the shed I came across the pegs from my son's old freestyle BMX

Not entirely sold on them look wise, but it is comfortable!

[90GTVert]

Nice. Custom pegs are one of my favorite mods. Being able to place them where you want makes them so much more comfortable and it really helps on long rides.

[Raizer]

Got a snap last night, my mate picked up my exhaust after work yesterday, so I really did score a like new Stage6 for $100NZ!

The seller asked my mate to warn me that it's very loud
Hope to have it Tuesday.


Today has been somewhat productive, as I'd gotten seriously sick of having to lean the scoot against a lawn mower or what ever to work on it my first mission was to make a stand of some sort.
So using the Sepia ZZ centre stand and a few off cuts I came up with this ugly but strong and functional mess

Will keep an eye out for a stock AZ one or see about getting something a bit nicer bent up one day I think!
/Make a side stand

Next was the pegs, got them in a comfy spot where I can have my feet up or have my toes up on the pegs and heels on the frame (might add a pair of heel rests)



4L became 4.5L

Still need to grind the welds back and think I'm going to try silver solder over them to seal off the few leaks.

Started mocking up the petcock location, had to twist the fuel fittings around but it'll work.


And as it sits now

Still not entirely sold on the look of the seat.

Those bars are temporary, just whacked them on to get a better idea of seating position, the straight bars were way further forwards, plan is to use a BMX stem and bars.

Still not sure what I'm doing headlight and control wise yet.


Edit: The ZZ seat doesn't look too out of place to me, but would mean the fuel tank would be totally exposed/could be replaced altogether with a larger one.

[Raizer]

Today I went from these

Stunningly ugly pair of factory bars, clearly designed to be buried under a ton of plastics.

To this



Now I just need to find a rear brake lever, throttle, longer cables, grips and bore out the clamp on the master cylinder to suit the 22mm bars.

[Raizer]

I've ordered a pit bike clutch lever with starter cut off switch, so that should do the rear brake and there is a few sellers on Aliexpress that will do scooter rear brake cables made to the length for about $7 US so I'll order one as soon as I finalize what bars I'm going to use and know exactly what length cables I need.

Exhaust arrived at work this morning, first thing I did was cut out the restriction tube!


Test fitted it



Sure looks the part imo!





But of course it's never that easy for me...


Shouldn't be a major to get chopped and tig'd, I hope.



Local radiator shop reckons worst case $50 to weld a hose barb onto my tank, pressure test it and then braze up all the leaks.

I think he's underestimating just hole many holes I've managed to weld into it!





Thinking that even though there comfy, the bars are probably a little high, these might be a bit better www.trademe.co.nz/Browse/Listing.aspx?id=948277550

[Raizer]

Nothing exciting, just sorting out the exhaust.

Finally had my mate take his VW home, was meant to only be in my workshop for 2 days, it's been closer to 8 months!!
So now I've got room to work on the scooter

Note the angle of the pipe, that's not right at all!
Realizing the Mineralli (I presume) mount is never going to work on my Morini I started making a mock up, angle has sure improved and the massive gap between the bottom of the case and the pipe closed up a lot



It's put the header in a nicer spot too, should be just a case of cutting the head pipe off at the first weld, cutting the flange off, rotating both and welding them up



Also thinking I may cut the stinger off the chamber and rotate it a bit to bring the silencer in a bit as it's a fair way out at the moment and I don't exactly have any plastics for it to avoid!

[Raizer]

Had a go at making the new exhaust mount, looking through the steel I've got sitting around I could only find 1mm and thinner sheet or 10mm and 15mm plate.
Obviously none of it was going to work, came close to giving it up for today as there's nowhere open on Sunday to buy steel, until I spotted a few old saw blades up in the rafters!


It's 3.4mm tool steel, super hard and also super hard to cut or drill!


Killed a couple drill bits drilling the 2 holes I got done, but with some more trimming up It's going to work well!

All the Aliexpress stuff I've ordered for this build is starting to arrive too, flasher LED flasher units, new reg/rect and a pile of heat shrink turned up yesterday.

[Raizer]

Finished up shaping the bracket today, still need to weld on a spacer tube and paint it


Sits the exhaust in a good spot I think


Then after a lot of contemplating I decided just to go for it, picked up the angle grinder and went at my shiny pipe!

Will clean out that port I think!

Should be a quick job to have it joined back up at least

Using both hands I can get it so there's no gaps.


And I love Aliexpress!

[Raizer]

Got my tank back today, really ticked off about the fact it's gained 5 small patches of braze, but only lost 1 maybe 2 small leaks.

Thinking of going with a brace between head tube/seat area as suggested by a mate, but rather than putting a bike tank on it, I'm thinking of using maybe 3" tube or rectangle section and using it as the tank.

Something like that, thoughts?

[Raizer]

Aliexpress lights seem all good!

There only on loose to have a look at them, but should work nicely!

And decided to try get the exhaust sorted finally, so took the pipe and engine down to Pit Stop (exhaust and servicing franchise, not that many places open on a Saturday).

The woman there quoted "$100 to $150" for the 2 welds, I put my engine back in the car and bid her good day!

Found a place in the subdivision where a guy was welding up a logging truck exhaust in the yard, so I stopped and asked him about it, 15 minutes later it was all tig'd up

Asked him how much I owed him, "if you've got $10 in your wallet it's $10, otherwise free", as I didn't have any cash on me only my card, I went and got him a box of beer which he was rather happy with lol.

Showed him my fuel tank when I dropped the beer off, reckons "it's f**ked and not worth f**king with"

But then said it'd take him 30min to draw one up on the computer and stuff all time to weld it and as he's got a pile of 1mm stainless sheet left over from a job I'm getting a computer designed, water jet cut, SS tank for next to nothing!!

[Raizer]

Brought one of these

Turned up in a box that looked like it'd been kicked along the whole way from China.
Rev counter works, but only settable for 2 or 4 cyl meant to be set for a single from factory, speedo works, fuel gauge seems to.
None of the warning lights work though and I had to cut it out of the casing to fix the mashed terminals from the rough shipping.
Would be mint for a 2-4 cyl go kart or something.
Seller has refunded me most of what I paid, so once that clears I'm ordering one of these


Still waiting to hear back about my new tank.
Ooh and its now got a functional rear brake.

[iwiketuddlz]

Very nice gage..!!! How much was it?? You got from eBay?

I also like the tube idea for a gas tank..!! Really creative man
I think I have seen a kinda off road scoot with a gas tank like that,, can't rem the name of it though

[Raizer]

The first one was $34US from Aliexpress, the new one is $40US, also from Ali.
Both are findable on eBay too, just not as cheap, but you'll possibly find a seller that actually packs it with a bit of protection!



Just thinking about it the tube tank idea came in part from a Puch a member of the car club I'm in built a few years back
i.imgur.com/mTGXhSz.jpg

[Raizer]

No tank as yet, but have made some little bits of progress.

We drilled the stock master cylinder out from 19mm to 7/8" on the mill art work, is tons of meat to do it, but it was very tight to get the drill between the mount bolts!


Made a little bracket and mounted the hall effect sensor for the speedo, new one takes the same sensor so figured I might as well get it mounted now.


Discovered the steerer tube on the fork is hollow, so the hall effect wiring can be routed through the fork.

Also brought a pair of clamp on mirror mounts, going to use them to mount the speedo and possibly brackets to hold the indicators, prototype (read quick hack) bracket makes me think it'll work nicely!


Also still mucking around with my loom in the ultimate design program that is MSPaint

Using a bridge rectifier and a capacitor to convert the normally AC headlight power to DC for the light I've got coming.

[Raizer]

Got the headlight mount mocked up, still working on indicator mounting.

That angle section isn't the light mount, I cut and folded it to attempt indicator mounts after the photo.

Got a new throttle cable as well as longer rear brake cable and SS front line from Aliexpress, both seem decent.
Rear cable is perfect length but I've way over estimated the front line so will need to get it cut down and another banjo crimped on.
/probably cheaper and easier just to order another one the right length.

New gauge arrived today, much happier with this one so far!



/still no fuel tank.