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
