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Post by kevin55950 on Oct 8, 2012 9:37:58 GMT -5
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Post by kevin55950 on Dec 29, 2012 3:42:26 GMT -5
No update for a while, I'm rebuilding a 2007 Aprilia SR50 DiTech that I already owned... The guy that brought it has broken down the engine so I'll put a Polini 70cc engine with new crank & bearings. Trying to look better, he installed checker-plate aluminium foot rests, but he used 2" long wood screws... that wear trough the oil feed line. The hoses on this scooter are made of stiff rubber so it just blocked the oil feed line, merely no oil dropped on the under panel, so it was hard to see. Also he was lucky, the screw was near the coolant lines... Cylinder is not round anymore and piston rings are way too thin, that's why we brought the 70cc kit. (A local shop wanted $1400 just to change piston and ring). Here are some pics: When it was mine:     And now, the damage... 
Here a little video of the broken crankshaft bearings
   Sorry I wasn't able to resize the pictures a lot... My project on my Bw'S now is to make a new hood and rear panels to have a more modern, rounder-styled scooter. Here are the pictures: I'm at my first experiment in molding and fiberglass so... That doesn't look as great now but it will be better later as I get experience ! Aerox style hood (well I used clay to make it at first but it just became too dry too soon so... I'll do it better next time !   Here you see it started cracking and falling apart.. I have most of it in one piece that I'll reuse later. The rear panels, I use a Aerox headlight I used to make the hood but because of the hood bracket on the frame I'm not able to use it as a headlight.    (It's now around 2-3 inches shorter).  Not looking good now, the shape is far from final it's just the rough base. The urethane foam I used for it was making big air bubbles everywhere, which one do you use? I used the Great stuff brand one. |
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Post by aeroxbud on Dec 30, 2012 17:25:57 GMT -5
It's starting to take shape  |
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Post by kevin55950 on Jan 11, 2013 23:49:26 GMT -5
Yes! I cut the rear part where the brake light was beacause it became hard like cement and nearly impossible to sand :lol2: Some work of this week:   Making a solid fiberglass base for the mastic.  Needs more putty, I'll get some tomorrow I'm looking to add handle for passenger, but I have no idea.. It's hard to find a way to fit a handle that will look good. If you have any idea show me some pictures , Thank you ! |
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Post by kevin55950 on Jan 26, 2013 2:07:49 GMT -5
Little update from today. Working on a surface that is all mastic is way easier. I applied a light shiny primer coat to see, with the reflection, where I'll have to shape it a little more. There is a lot work to do for the under panel because of the misplaced gas tank on those scooters.  How does it look ? EDIT: Finally, I think it might look better if I figure how to make a new gas tank that isn't in the way of the under panel. It will look way better ! I don't want to put it in the seat compartment as far as possible. |
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Post by 90GTVert on Jan 26, 2013 7:53:27 GMT -5
Looks good so far. If the under panel is gonna be a separate piece that bolts/screws on, I don't think it would look bad with just a cutout for the gas tank. It would still smooth it out a lot, and that would be way easier. If you wanted to make it go over the hump, you could maybe turn the rear face into something useful with a little more shaping. Make it a tag mount or spot for a sticker (not sure what you guys use there).
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Post by kevin55950 on Jan 26, 2013 10:00:57 GMT -5
I'm using cardboard and masking tape for the under panel, and the rest is filled with urethane to save some of the Bondo mastic weight, with a layer of fiberglass between the urethane and the mastic. The rear light is held there with masking tape and fiberglass.
I don't know if it will look great with something that takes the shape of the gas tank, it's made strange , like the under panel has to make an S under the scoot where the wheel passes. It will be screwed there. I'm planning to make a mold of the rear and make it all fiberglass to save the weight of the heavy mastic.
Finally, it's not so hard to put the gas tank in the seat compartment, if I remember, I can keep the seat lock bracket there without the gas tank.
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Post by waltinhawaii on Jan 27, 2013 2:52:26 GMT -5
Your early pictures had a 'shiny spot' on the bottom of the cylinder? A friend who used to work on bikes a lot and has lots of experience with cheap chinese parts says this is from the cylinder being so thin. My newly purchased cylinder (just barely opened the box) has the same problem (53mm lc). I think they bore and hone the cylinder quickly with large heavy cuts and the cylinder, being so thin, flexes away from the cutter and hone. So the finished cylinder springs back and is too tight in that spot. I've been told a good honing job (not with the flex hone, have to use a shoe type hone) can fix that, but I have not yet located a good hone.
where is a good source for lc radiators?
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Post by 90GTVert on Jan 27, 2013 9:01:40 GMT -5
eBay is a really good place to find all sorts of radiators. Search for radiator and names of small dirtbikes and ATVs and lots of stuff comes up. Searching for "scooter radiator" usually brings up a few. Some of the used stuff looks good and goes cheap.
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Post by aeroxbud on Jan 27, 2013 13:45:54 GMT -5
It looks better every time you put a new picture up I would just go round the tank, then if your not happy with it change it later. |
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Post by kevin55950 on Jan 27, 2013 14:15:08 GMT -5
I'll show you a picture of what it looks like without the gas tank. This is a greenwood rear panel, that were made some years ago in Canada for the Zuma. You have to modify the frame a lot to fit those, put the gas tan in the seat compartment, and they aren't really designed to go on the street because in here it's kinda illegal to change anything on the scooter, and modifying the frame and getting caught will take your scooter out of the streets forever. ![]() They're beautiful, but now rare as they are made of fiberglass by people like you and me, and the guy who made them stopped since some years. If I take out the gas tank, and make an engine case spacer, it will look way better without the gas tank, with a flat under panel. I'll try to tape around the gas tank and send a picture. I found some good radiators cheap, with polished sides and improved cooling: www.ebay.ca/itm/Suzuki-RM85-RM-85-02-09-06-07-alloy-Aluminum-Radiator-/280665826452?pt=Motorcycles_Parts_Accessories&hash=item4158fca494&vxp=mtr&_uhb=1#ht_1494wt_1163This model is used a lot for conversion because it has the filler cap on the radiator and they're small, perfect to fit them on the plastic behind the wheel. On www.scootertuning.ca we have one that fits under the hood depending if you can do it on your scooter, but you'll need a tank reserve as there is no filler cap on those. scootertuning.ca/en/277-liquid-convertion?p=2 We also have a hone for your cylinder : scootertuning.ca/en/tools/39058-grit-stones-motoforce-for-cylinder-hone-3-pieces.htmlThank you for your comments ! I'll continue to shape it and figure how can I make an under pannel. |
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Post by 90GTVert on Jan 27, 2013 15:50:26 GMT -5
That looks amazing, but I'd take under seat storage vs a smoother undercarriage any day unless it's gonna be a show scoot. The storage is one of the joys of owning a scoot vs basically any other type of bike IMO.
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Post by kevin55950 on Jan 27, 2013 18:06:02 GMT -5
And reshaping the gas tank is a long and dangerous work... Making a new one will be hard because of all the surrounding components and brackets. I'm trying to figure how to make it look great with the gas tank there...
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Post by aeroxbud on Jan 28, 2013 6:52:03 GMT -5
X2 it has got to be the best thing about scooters. After years of owing bikes it is so nice not having to carry a helmet round with me.
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Post by kevin55950 on Jan 28, 2013 7:00:50 GMT -5
Yes, but I have to carry an oil bottle, a belt, some tools and a 1L small gas tank in case I miss gas, always full throttle with my 24mm carburetor... Take more gas than my jetta lol. It's hard to fit an helmet with all this stuff.
My SR50 needed specifical Aprilia helmet to fit well in the seat compartment. Other ones were fitting but were all scratched on the rear or the seat closed so tight that I had to change the seat lock. I was used to carry my helmet.
But I'll try yo figure how to make it look clean, I've put the headlight this way to have a less big curve on the underpanel.
I'll try with cardboard and tape but it will be hard to make the resin hold on this ( damn gravity... ) as putty will crack everywhere without a solid base. That's the main reason I was looking for a flat pannel.
EDIT: Well, I found Bondo Glass ( mastic with fiberglass fibers in it) that is more prone to stick than the resin and fiberglass... but it's hard like cement when it comes to sanding.
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