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GT6MK3

Vespa smallframe

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Am now attacking the cowls upside down, using the seat bolt datums for reference.  This may or may no work out...

 

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4 hours ago, GT6MK3 said:

Am now attacking the cowls upside down, using the seat bolt datums for reference.  This may or may no work out..

The technique is sound.  Some of the curves look disturbingly different side between the two sides........ that last pic.... :pinch:

May the force be with you!

Nick

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Left the ram in the engine side cowl overnight, and after a bit of stretching, I was able to mark. drill and bolt the nose into place.

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The two curves were still a long way from correct though.

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Time to channel my Billy West

Use the clamps Clamps!

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Time to pull out a high tech solution - 3/16th nuts and bolts.

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These worked a treat!

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Isn't she pretty...

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Getting close now

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Starting to see a glimmer of light at the end of the tunnel.

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When you have finished the Vespa, I have a pile of swarf I have been trying to assemble back into shaft if you want a challenge! :biggrin:

Admiration for the level of OCD commitment shown here

Alan 

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Progress...

The inner guards are once again set in place, squared up, and welded in

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and with that, all it took was some slight relieving of the engine mount through holes for the outer shells to fit on perfectly.

 

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Whoohoo!  

After the test fit, off it all came to drill holes

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holes, 

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and more holes.

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One hundred and thirty three holes in total.

So, all the parts are now clamped with as many clamps as possible,

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 Buffy's ready for a welding frenzy tomorrow afternoon.

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So this afternoon went like this:

Clamp clamp clamp clamp

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Clamp clamp weld weld weld

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Weld weld weld weld

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weld weld weld weld

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Weld weld weld weld weld weld weld

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Rest.

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Grinding starts tuesday...

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I reckon you've captured it there :thumbsup:  Will be the best built Vespa on the planet......

Not had any more parcels yet...... should I have done?

Nick

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Yep, she's getting there.  I'm learning a lot about the logic of monocoque structures, and it's fun, (except when it's not.  Like all motor projects!) .   The Italian designers are more reliable than the parcel senders, I suspect there's another plan coming there.

C.

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Presumably there is reason why the smallest gear appears to be twice as wide as it needs to be?

Never had much to do with bike gearboxes. Sequential dog boxes........

.........very sporting on the car world

Nick

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1st also gets double duty for the Kickstarter.

Behold the fruits of today’s labor at the lathe,

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dummy bearings to let me test build the engine

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Still got to weld on the legshield - it's just getting marked up atm.  Then the tricky horncast has to be let into it...

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Got 2 Spot welders - my handheld and Mat's floor mounted beast, but neither seem to be able to make a decent weld through weld through primer.  Given that steel in the spine is going to be in the wet and cold, I want the primer in place, so it's back to plug welds...

 

More work Friday arvo.

Finally figured out how to put the choke actuator back together.  Simple when it's done, harder when your looking in a box of bits.

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Then ran cables, lots of cables through the spine for use installing all the control cables and wiring later.

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That's 5 bicycle gear cables, 3 runs of lightweight balustrading cable and 4 runs of mig wire just in case.

Time for these two to be properly introduced.

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Some gentle squeezing on a well lit table with plenty of room in the middle of the factory to begin the process, with final measuring, marking and tweaking taking place.

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Then a buttload of clamps...

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That many clamps adds a _lot_ of weight!.  Turning it over with all the clamps was tricky and took two of us, and we added a table clamp for stability

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Ready to start plug welding.

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The rule for plug welding is to double clamp every hole individually, and wind it up as hot as you dare.  Mating the thin legshield to the much thicker spine and getting good penetration is tricky.  I'd much rather risk a burn through and have to do a fair bit of grinding than not get good strong penetration.

Setting up the clamps every time, and doing it right means each of these welds takes about a minute of setup before the 3 to 5 seconds of bright light.

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So after a couple of hours of setup and measuring while clamping, welding just the two sides of the base took well over an hour. 

But after turning it over, it was good to see the strong penetration achieved.

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Next job will be to re clamp, and weld the front of the legshield.

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(Believe it or not, I need to buy another quite specific clamp before I do that).

But, Buffy's starting to look whole again.

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Progress.

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