Need a bit of help please

[sparklymarkly]

Almost ready to get my GP painted now but need a bit of advice on a couple of things please.
I intend to fit a hydraulic front brake (which I haven't got yet) & don't want to start drilling holes after the headset is painted so could anyone give any advice on exactly where to drill to allow the brake hose into the headset so I can do it in advance? Also, what size hole?
I also have a problem with my horncasting - there is no way I can undo the screws that hold the grille on. Tried soaking in WD40 (filled up the holes from underneath & left overnight) but no joy. Now the screws are a bit chewed up.
Would it be better just to drill out the old screws & retap the threads afterwards?
Finally (for now!) before I get my forks blasted & coated I am getting upper shock brackets welded on. I see they have a sort of 'shaped bit' that gives a guide on where to weld them but doing a dry run in that position, the shock doesn't seem to be quite parallel with the fork - is that correct?
Any advice welcome -Thanks in advance!

[soulsurfer]

You really need to dry build with your master cylinder and hose if choice to determine hole size and position.

You should try to remove the horn grill screws for painting.

Your dampers should be parallel with the fork leg, see Sticky's latest book for damper bracket positioning.

Lastly, don't rush things and double check everything, dry builds are great for sorting out the unexpected and there are no shortcuts for a decent build

[Mickey C]

i'd agree with doing full dry build.

for hydraulic hose most i've seen tend to go thru headset bottom but i've put mine through the headset top - just figured cheaper to replace than bottom if i have a change of mind. dry biuild gives you choice where to put it.

i've had horncast grill bolts that were swines to shift - if drilling just be careful becuase of the soft alloy of horncast.

good luck with it
Mike

[Hong Kong Phooey]

Just a point on the removal of the grille, I had the same issue and even mounting on a piller drill it was very difficult to drill out straight without the drill wandering into the cast aluminium horncast. Leave for longer soaked in wd40, if poss cut some deeper slots in the screw heads which is not easy as they are sunk in slightly. After a good soaking dry off and heat, the horncast will expand more than the screws, maybe enough to free. Good luck.

[sparklymarkly]

Thanks for the replies Guys.
Good point re drilling he horncast - I might try the heat thing before getting the drill out.
Had another go at them this afternoon and still no joy. The bottom screws (under mudguard) are snapped off anyway so they'll need sorting.
Shame really as it's a lovely condition Innocenti cast apart from that.
I do see the point of the dry build but my problem is that I haven't decided what brake I'm getting yet (suggestions welcome!) and the mounting is dependent on whether I go for a GP or LI switch housing (I'm fitting indicators so probably going to use or ba$tardise an Li/Serveta switch to do it). Any photos of anyone's holes (oo err!) welcome.
Had another mess with the shock mounts today (rainy Sunday + all day in garage!) :bigsm:
Assuming I've got the top mounts right, the shock is not far off but not quite parallel with fork tubes (see photos if I can add them now).
NO I CAN'T! I'll come back to that!
I should point out that it may be a) because the forks are only partially assembled (just bottom links in, no internals for testing) and that the bottom mounts are those awful clip-on things. I will be geting proper new links.
Do the top mounts face straight back when mounted correctly or are they angled slightly - that would explain a lot.
Sorry for the rambling post - I haven't done much Lambretta work since 1987!
Cheers.

[sparklymarkly]

After a good soaking dry off and heat, the horncast will expand more than the screws, maybe enough to free. Good luck.

Followed your advice, used a blowlamp very gently & have just got both grille screws out without damaging anything! Thanks!!
The bottom ones are definitely going to need drilling out & retapping but that's something for another day. Chuffed for now -cheers.