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Andrew ITA

150 LD MKII - Build thread...from rust to glory

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Exhaust installed...as usual, nothing lines up, had to modify the mount slightly and then slowly bend everything in place

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...cables. I've installed an extra wire in the loom, that will provide regulated 12V inside the glovebox for accessories (phone charger).

New lower steering cup, license plate holder and sprint rack

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Entire front end is now installed...I used 23 1/4 inch balls in bottom, 36 1/8 inch balls on the top. Works much smoother than caged bearings. Took some patience though...

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More cabling work...had an issue with the steering lock, the locking pin was not centered on the first hole in handlebar support: the lock had to move inwards. Without a lathe, I improvised...by keeping a steady hand, you won't know the difference :)

 

 

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Cabling is almost done, only missing the rubber sheathing that I still need to measure and cut. Unfortunately, the gas cable outer is a little too short (due to the PHBG), I'll try to see if I can add another adjuster to lengthen the assembly and gain an inch

 

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Cabling is now done, including the sleeves that were a major pain.

 

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Installed tank, choke and tap, no leaks.

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Front horncast assembled and air scoops finally done and ready to be installed!

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I figured it took about 10 hours to restore the air scoops alone, but  it was worth it...these are are an original set from back then, not a repopIMG_20170222_103636.jpg

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...getting closer! just finished the electrical connections and the cowling (as always, a big pain to align)

 

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I've also decided to make a minor modification to the sidepanel latches. The Casa kit comes with a cast bushing that is pretty rough: during the dry build I noticed that sometimes the latches would get stuck half-way and not close properly unless I manually force the bushing from underneath with my hand. I decided to swap them for others made of brass (from scootopia) that are machined smooth. This should improve the situation quite a bit

 

 

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Real nice!
I like that rear "sprint" rack (don't think I've seen them on an LD before?). Where's it from?

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Thanks! i like it because it's small and streamlined, it does not interfere with the sweep of the rear. 

The sprint racks are very hard to get for the LD, I found it on the ebay UK about a year ago, I think I got the last one available. I will send you the merchant info via PM

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No it's specific for LDs, when I bought it a year ago there were only 2 available. Try to contact the guy and see if he has more stock coming in...the title was LAMBRETTA SPRINT RACK LD Models LD SPRINT RACK IN STAINLESS

 

 

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...if you ever worked on a LD, you know...these rubber parts always end up giving me trouble...took an entire afternoon and ended up with terrible hand cramps.

 

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It really took forever but I'm happy I was also able to finish the clock! I tried to tap it and shake it functions properly, no time skipping. I will test it to see if the vibrations affect it in any way. I wish I could find hands that were little thicker, unfortunately the OEM shape was quite unique and these are the  closest ones I could find. 

All in all I'm really happy with how close I got to the real one when it comes to overall look

 

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14 hours ago, Andrew ITA said:

...if you ever worked on a LD, you know...these rubber parts always end up giving me trouble...took an entire afternoon and ended up with terrible hand cramps.

 

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Lots of rubber bits fit easier after they are boiled in water first.  Amazing how much more pliable they become.

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Thanks! I"ve actually tried that (submerging them in boiling water for 10 minutes) and also smearing soap on the inside to make them slip better...made a lot of difference, from level impossible to level (painfully) possible! :)

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Well I'm glad the rubber saga is over, more progress done! 

Floor strips, footboard/floorboard extensions, glovebox.

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This is my final setup. Both clock and speedo are backlit, feed is taken from black cable (rear light) which is 12V AC (I added a fuse in the circuit) then goes into a KOSO AC/DC converted, which feeds 12VDC to the instruments. The clock itself is powered by an E90 battery that you can simply change from underneath the instrument, probably good for a couple of years.

A second feed comes from the Varitronic regulator, the red 12VDC battery trickle charge is used to power a USB port for mobile phone charging. That circuit is fused too.P1080672.JPG

 

Both fuses are installed between the steering column and the legshield.

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I'm not really happy with the cable routing, throttle too short and gear too long, I will need to do some rerouting, cut&lengthen type of work.

Besides that, I'm now left with fixing the front brake clunk (hub locking tab is worn).  I'll probably fabricate a copper shim to take out the play

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ok, just fixed the last PITA for this build (or at least I hope). 

I've taken the slack out of the front hub by adding a copper bushing that I made out  of a coupling I found at Home Depot. Will see how long it lasts, so far it seems to be working just fine

 

 

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