SS90 (copy) bodywork preparation etc

[Knowledge]

6 Feb 2012
The shortage of acetylene at BOC will cause me a problem, as I have just run out.

I won't be able to complete the welding without gas. I'd just ordered new gas hoses too.

I'll have to get on with some other bits and bobs that don't involve oxy-acetylene welding.

(The acetylene shortage went on for many, many months)

[Knowledge]

8 Mar 2012
Sorry for the lack of progress updates. The main reason has been the lack of progress.

I have finished forming the groove around the outside of the cut-down legshields. It looks good (quite hard to show on a photo), but it will need a bit of finishing off when I have a volunteer within reach.

I also need to get the inside of the tunnel (and the N/S panel) blasted, but my tame blaster needs good weather to blast (he blasts outside) and the weather has not been too good of late. The forecast looks good for the next few days so I might try and drop it off tomorrow.

Once the blasting is done, I can get on with fitting the floor.

Still no acetylene.

[Knowledge]

9 Mar 2012
I took the frame into the blasters this morning and it was done in the afternoon. Sand blasted and etch primed for £45 and I collect it tomorrow at 8am.

Good service.

It is a pity I am so busy this weekend, so I still might not get the floor tacked-on.

[Knowledge]

10 Oct 2012
It has been a long time, but work has recommenced. OK, I haven't done much work, but the frame now has a floor. Hooray!

There is a lot to tell, but it will have to wait for later. Meanwhile, can someone remind me of the guy in the Lake District who has the small frame jig? A contact number would be useful.

Thanks in advance, and I'll get the camera out before the next post.

[Knowledge]

14 Oct 2012
Sorry I’ve been away for so long, but there is a long story attached.

I needed to tell the story of the build without disclosing who I am, because I was building the SS90 for my son as a surprise graduation present. Will is known to some of you, as he attended the original small frame shoot-out organised by Sticky at Diablo’s in Nuneaton.

He was spending 4 years obtaining a Chemistry degree at York, well away from the family home in Ipswich. However, it did rely on me hiding the frame if ever he returned home, as he always likes to see what I am cooking in the shed. Occasionally he pops into the SFF for a bit of scooter porn so I was concerned that he might see something he recognised, so every photo I posted needed a cloth as a backdrop, hiding the workshop fixtures and fittings.

All was going well, until BOC ran out of acetylene; my weapon of choice for welding. Although my brother-in-law lent me a MIG welder, I had to learn how to use it and to be honest, I’m still not that good with it. Then I started to build an extension on the house (and the workshop). I needed to spend far too much time on the house, and zero time on the frame.

Unfortunately, graduation came all too quickly and instead of doing the DIY SOS grand reveal at the graduation as planned, I put the headset in a box and wrapped it up for him. Back at the hotel after the ceremony, he opened the box with a mixture of wonderment and confusion. There was a bit of satellite delay and I then needed to explain that I also had the tank, frame, seat, lights, spare wheel covers etc etc. And that clinched it for him, and a large penny dropped. Big smiles and hugs followed.

OK, so it wasn’t quite what I was anticipating by way of presenting him with the bike, but at least I could rely on Will to help prep the bike on those occasions when he is home. Needless to say, he is very excited about the project, and I’m quite pleased that he is on-board for the rest of the build as I can ensure that the decisions that need to be made can be put through him.

I haven’t told Will about all the people who have kindly donated parts and time on getting the SS90 frame to this stage. You know who you are, and I thank-you. He will find out who you are from reading this thread.

The plan is to complete the frame and get it to John in Cumbria for a good dose of straightening on his small frame jig (yeah, not very local to Ipswich). Once filled, smoothed and dry built, Will’s cousin will paint it and we intend to swap the Polossi 136 motor from Will’s PK frame into the new SS frame. The engine is still healthy and making useful torque alongside the 13.6bhp. Al said it was one of the most torquey motors at the shoot-out, and it pulls a standard 4th gear beautifully. The electrics will be a full DC system using a Wassell regulator and a small battery hidden away somewhere. LED’s will be used to reduce power consumption where practical.

There is still more work to be done on the frame. I have put the floor into the frame and learnt a lot about spot welding in the process; some good, some not so good.



The area circled in red was rather challenging: We used a vice and a couple of temporary spacers to squash the floor-pan into shape.



The foot brake doesn’t quite line-up, so I’ll have to weld-up the round hole and put it in the correct position. I’m now repairing a rust- permeated hole around the rear light. You may recall how I rebuilt the rear end using a rusty rear end donated SteveC, and this repair is part of making good around Steve’s kind contribution.



I need help with locating a suitable SS90 style beading for the legshields. The ones I was watching on German ebay are no longer listed. Bummer.

Martin

[Knowledge]

2 Nov 2012

I took the frame to John Mac in Cumbria for a session on his jig, via Bridlington: a 730 mile round trip.

In order to address the issue with the oval engine bolt holes and ease the frame straightening process, I stripped off the old washers from the outside of the engine bolt hole and made two new plates.







The frame was put in the jig and then plug-welded the new plates into position once we were happy the frame was in the best position. Fortunately, with all the work we put into the engine bolt holes, straightening the headstock was easy.



Unfortunately, the jig experience has taught me that the frame is not as good as I had hoped. OK, it’s straight, but it is a bit short. The tank, spare wheel and seat will fit, but it is all rather bit cosy, and the steering column is a bit steep. It soon dawned on me and John that there was nothing we could do about it. In the photo below, the pointy end of the rod should be over the nipple, and it is about 20mm out. Ouch.


John is a nice guy who knows his jig very well. What surprised me was how easily a frame moves when you lean on it with a big lever. It makes you wonder what the frame is doing when you’re riding the damn thing.

[Knowledge]

28 Sep 2015
Work is ongoing. The frame is painted now and I have been busy making and fitting a wiring loom from scratch, fitting the cables, forks, front disc brake etc etc.

Will chose red, and it was a good choice. I had problems matching the suggested colour codes to real paint colours, so I took tony O's advice and used the current Piaggio red colour. In fact, it is the same red as my Gilera Nexus 500.

I'll post some photos soon, but it really needs to be a rolling chassis before I do, as it won't photograph well in the confines of the workshop.

So I am still working on it. Fortunately, Will has gone back to University (teaching), so I now have another graduation to aim for. Perhaps this time I will get it right and deliver it on the day.

[Knowledge]

12 Dec 2016
Very nearly finished.

The tail light and headlight need to go in, fit the exhaust, bleed the brake and fit the new number plate.

No photos until Xmas though. I'm such a tease.

[Knowledge]

24/12/16



Was it worth it? Will likes it.

[e type]

Just hit the like button ...Merry Christmas