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well it's not a car : my two wheel build ^_^ (picture heavy)

5045 Views 17 Replies 5 Participants Last post by  kingburger, 
kingburger
Hello guys and gals :)

& so to fill up my already somewhat full schedule, I picked up another project.
The rebuild of my recently acquired (June 2010)1979 Puch Maxi II moped. :eek: It's older than me!

A little history on PUCH:

The company was founded in 1889 by the industrialist Johann Puch and produced automobiles, bicycles, mopeds, and motorcycles. The Maxi is one of Puch's most well known machines along with the Magnum and Newport models. The Puch Maxi is a moped fitted with a single cylinder, 49cc, two stroke engine . The engine (mine is a ZA50) produced around 2hp and could propel the rider at speeds of 28 mph stock (I'm well over 30 mph :) top speed with a few added modification as I will state later) It was started using the pedals which could be engaged and disengaged from the engine via a starting lever so it could be ridden as a normal bicycle.

The moped before:


spec (for now hehehehe):
ZA50 engine 2 speed automatic
14mm intake manifold
Biturbo exhaust system
NGK spark plug
36 tooth rear sprocket
17 inch polished rims

First, I rode it around for a good while as is, then really really good fun times were had and a friend of mine who borrowed the moped after a few swigs ended up barrel rolling off the bike. He was ok but as for the bike, it resulted with a bent fork and minor scrapes on the crank case. It was then after that this moped needs a face lift :)
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kingburger
Re: well it's not a car : my two wheel build ^_^

September 4:
After much hours of procrastinating, I finally got down to taking all front assembly off (cables, wires, gauge, handlebars, control levers, front fender, front wheel). Except the damaged fork which will be removed along with the motor and the rear assembly.
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kingburger
Re: well it's not a car : my two wheel build ^_^

September 8:
After, looking online and finding out that none of the stores have EBR forks for the Puch Maxi in stock, it's time to go and post on all the forums I visit. Finally got a response from a bicycle forum. Newly acquired Dipper fork (it's not an EBR brand but it's almost the same :) $70) VS stock 'f*cked up' fork.
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kingburger
Re: well it's not a car : my two wheel build ^_^

September 14:
Took out the rear assembly as well as the motor and stock fork. Not much of a hassle, it's just like working on a regular bicycle. The only difference is that this one have a motor :p Draining out the remainder of the gas.
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kingburger
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Re: well it's not a car : my two wheel build ^_^

September 21:

After cutting 1/3 of the rear fender and sanding down the rough edges, I then on proceeded to strip the paint! Be careful not to get this stuff on your skin! It burns :sick:! It was real easy to get the paint out. I'm guessing that the olive color was the original paint.


Here's the end product after the stripping:


A friend of mine who I helped out on refinishing his Weds Sport rims, came over and decided to join in on the fun :) He cleaned the grime off of the engine and on the wheels:

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kingburger
Re: well it's not a car : my two wheel build ^_^

September 22:
A whole day of sanding and more sanding. I've also done some Bondo work on some holes that were put there by the previous owner. Here is the end result:
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kingburger
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Re: well it's not a car : my two wheel build ^_^

September 26:

The chains were degreased and started to primer the frame:



After finishing the whole primer process, I taped up the places where I didn't want the first color to go on (since I intended to go two tone on this :) )


On to painting (yes that's right, orange!) and later added Dupli-color burnt copper metal flakes:



I now have sparkles! lol.
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kingburger
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Re: well it's not a car : my two wheel build ^_^

September 27:

Went on to painting the second color (a few, coats of black): you can see the aftermath of the previous paint session on the background. The splatter was from another project. lol. butter fingered I was back then.


Done with the painting of both colors. Went ahead and clear coated the heck out of it. I'm still debating on adding Rat Fink styled artworks as an accent to some areas of the frame.
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kingburger
Re: well it's not a car : my two wheel build ^_^

September 29:
I got bored so I decided to paint the exhaust engine black with the burnt copper metal flakes.
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kingburger
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Re: well it's not a car : my two wheel build ^_^

October 8:

Mock-up. As far as the handle bars look, it's actually perfect (well, not really....did some thinking and I'm gonna need a much more comfy reach). Added carbon fiber (yeah, that's right) carbon fiber headset spacer. gotta have some sort of carbon in it...lol. Picture this with some PUCH long seats. heh-heh-heh. :naughty:




Things to get are some 22mm clamp clubman handlebars and a Puch long seat which I hope i have enough money to get them this coming Monday or just modify my current saddle to sit low like this one for example:
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kingburger
Re: well it's not a car : my two wheel build ^_^

Thanks for looking guys. Tomorrow is Monday and that means it's time to check the piggy and see if I can get the parts needed.

List of errands:
-work
-check out local motorcycle shop for handlebars
-go Lowes/Home Depot for electrical stuff and look for that awesome door lamp
-go online shopping for the long seat and the cables needed
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kingburger
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Re: well it's not a car : my two wheel build ^_^

October 11:

Ordered these today:
- front brake cable
- rear brake cable
- throttle cable
- two speed clutch cable
- Puch long seat

What I acquired today :)


That lamp is 12V which is perfect because my CDI is also 12V yay!

Oh yeah.... :yes:


can't wait to rig the mount on this thing on Wednesday.
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kingburger
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Re: well it's not a car : my two wheel build ^_^

October 12:

Well, instead of working on the unconventional headlight all day tomorrow, I decided to finish the fabricated mount.
tadaaah~ I won't splice the wires yet until I get the motor from Mr. Poon (who is currently refinishing the crank case cover for a polished look...don't know when that would be done)



Maybe later tonight, I'll start on modifying the front fender.
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kingburger
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October 14:

Look what came in today. TREATS!


The saddle sat quite high and I didn't like the look so I've already modified it to sit lower. Now it looks awesome!
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