'69 DL-235 thread... reincarnation

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'69 DL-235 thread... reincarnation

Postby spiderwebb » Sun Mar 09, 2014 2:26 am

started the engine rebuild w/ my guru today
learned a lot
matched the case to the barrels transfers
cleaned up the cases where needed
all bearings and seals installed
improved the wish bone to help it clear the case slightly for 5th gear perfection
cyclone test fit dry to figure out the shim needed so it is within spec
productive afternoon

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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Thu Mar 13, 2014 12:04 am

- cyclone rechecked for spec one more time, thicker of the two provided tree shims fitted and then everything was rebuilt for the last time w/ lube
- crank installed and checked for clearances = perfect
- mag flange finished and checked (bearing packed and correct gasket used for crank web clearance spec
- clutch basket and front sprocket checked for alignment (figured out the correct shim to swap in for the next work session)
- and other small things like why the lower chain guild is important

good day

would have moved onto chain and top end but the 83 link chain I bought wasn't in the box it should have came it... the box said 83 link chain but it was a 81 link chain.

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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Thu Mar 13, 2014 7:11 pm

my lambretta RT-225 build thread pics are all on the bottom of the following link:

http://www.flickr.com/photos/53235515@N ... 701433548/
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Sat Mar 15, 2014 6:59 pm

Hot Rod Al is going to lighten up my flywheel this week also
it is currently 2800 grams

I'll be going back up to portland to wrap up the internals, top end this next weekend and mount into the frame. I'll bring up the rest of the scoot because Mike wants to see it all done right even though I can do it easily... got to make me guru happy.

Since I am bringing the scoot up his shop I might as well do some needed front fork work
- full rebuild and upgrade
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Fri Mar 28, 2014 2:19 pm

I had Hot Rod Al lighten my Casa flywheel to around 2025 grams
very stoked

before:
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after:
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Sun Mar 30, 2014 10:22 pm

got a bunch done
- top end all set up and checked 3 times = squish is 1.11mm and port timing is perfect
- figured out that I need to run "matching" brake pads with whatever hub I want to rock
- chain length is still a issue due to the number of possible chain guides used (complicated assortment)
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I'll be finishing up this build over the next few months, install it in frame, mount long range tank, new gas tap, stator, flywheel, all tin (I have to make up a tin spacer to buy on so the head tin fits), floorboards and set up carb system. I promised Mike that I'll trailer the scoot up to his garage for the 1st startup.

Then we shall pull front fork and do some upgrading on it too
- disk front, non progressive springs (top tip by JJH), weld on dampener mounts, ...ect

:) :)
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Mon Apr 14, 2014 7:22 pm

built up both rims...

100/90x10 Heidenau K61 on BGM rim
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steps:
BGM lambretta rims build up... use hair spray for ease of assembly, nuts without lock washers to get started, a little air in tube to prevent it getting pinched between rims, check tube is clear often and slowly bring rims together. Once all tight remove one nut and add the lock washer. Add blue lock tight and nut... torque to spec. Repeat with the remaining 3 rim nuts = All done. I filed the rim air hole since it was a bit sharp.

**TOP TIP **
- use hair spray for assembly since if you use soapy water you can have rapid inner tube failure as the tire spins on the rim = no good = pop
- on important rim nuts (the 4 that hold rims to the hub) DO NOT use a flat washer between the lock washers and rims...!! As E Dave told me this can lead to a situation where the flat washer can spin with the lock washer and nut in effect allowing the nut to get loose = off comes the nut and rim from hub = :(

if your using a nylock nut then you wouldn't use a lock washer anyway so a flat washer is perfectly OK in this location

be safe people
check your nuts often

cough cough
:mrgreen: :mrgreen:
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Fri May 09, 2014 1:28 pm

fixed the rear brake / drum issue

turns out that the new brake pads where just too large for my SIL rear hub
slapped in a used innocent set and all is spinning cleanly

:) :)
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Re: '69 DL-150 thread... reincarnation

Postby joe » Fri May 09, 2014 3:53 pm

spiderwebb wrote:fixed the rear brake / drum issue

turns out that the new brake pads where just too large for my SIL rear hub
slapped in a used innocent set and all is spinning cleanly

:) :)


cool
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Sat May 10, 2014 7:25 pm

here is my write up on chain tensioners and gearing in the 46x19 (or 20) tooth ratio's
I'll be building up a 46x19 w/ 82 link chain ratio
might grab a 47 clutch basket so I can run a 47x20 w/ 83 link chain next year

if this engine red lines @ 9000rom that is 98mph
wow

46x19 w/ 82 link chain, no tensioner but one is needed
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46x19 w/ 82 link chain & MBD top push "up" tensioner, 2 studs
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46x19 w/ 82 link chain & Jockey top push "up" tensioner, 2 screws
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46x19 w/ 82 link chain & Jockey top "down" tensioner, 2 screws
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46x19 w/ 83 link chain & Jockey top "down" tensioner, 2 screws (this combo would work but a 82 link chain is way better...!!)
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46x19 w/ 83 link chain & Jockey top "down" tensioner & scootRS lower, 2 screws = chain rubs on plate everywhere
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46x20w/ 83 link chain & Jockey top "down" tensioner & scootRS lower, 2 screws = chain rubs on plate everywhere
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46x20 w/ 83 link chain & Jockey top "down" tensioner & scootRS lower, 2 screws = chain rubs on plate everywhere
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46x20 w/ 83 link chain & Jockey top "down" tensioner = 2 screws used = chain clears plate (one stud could be used)
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46x20 w/ 83 link chain & Jockey top "up" tensioner = 2 screws used = chain hits case
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46x20 w/ 83 link chain & Jockey top "down" tensioner = 1 stud and one screw can be used (you need a shorter stud to allow the threads to be right length). Cable block stud is right length
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46x20 w/ 83 link chain & Jockey top "down" tensioner = 1 stud and one screw can be used (you need a shorter stud to allow the threads to be right length). Cable block stud is right length
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46x20 w/ 83 link chain & Jockey top "down" tensioner = 1 stud and one screw can be used (you need a shorter stud to allow the threads to be right length). Cable block stud is right length
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my notes:
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Sat May 10, 2014 7:30 pm

when this tensioner is available I'll buy one or two for the spare shelf

bad ass MBD idea

this is a spring loaded auto "push down" top chain tensioner:
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Tue Jun 24, 2014 2:00 pm

got back on this project today...

Kickstart lever ground down due to it hitting the MBD clutch pressure plate and not letting the chain cover fit to case perfectly. I built up the chain case cover and when I set it into place the cover wouldn't sit flat... thats not good. Rotated the rear hub (and transmission) and heard a little metal on metal. Looked at the kickstart shaft and saw some rub marks on the location I ended up grinding down a .5 to 1mm for clearance. The end result is a perfect fit:
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MBD clutch - steels and corks about to be installed using the right tool:
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MBD clutch in, Jockey pull down tensioner, 83 link chain and 20 tooth front sprocket (and a 5 speed gear box)
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8) 8)
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Re: '69 DL-150 thread... reincarnation

Postby joe » Tue Jun 24, 2014 9:01 pm

cool
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Wed Jun 25, 2014 2:47 pm

MBD reed flowed manifold installed:
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BGM exhaust slip joint flange installed (goo on the stud threads acts as a sort of "lock tight")
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next up is cleaning up the DL frame anfd removing the old 150cc engine... then throw it into the frame and hook up all the cables, add oil, install stator, ...ect
:) :)
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Re: '69 DL-150 thread... reincarnation

Postby spiderwebb » Tue Aug 12, 2014 4:28 pm

got this for the RT-235

35mm Air Striker PWK KEHEIN
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