Brake Cable Thingy & Seat Creation

First I thought I would share our work area as of recent. Since moving into an apartment Bill has been nice enough to let me use his back yard to work in, which i'm sure he prefers. He has been doing most of the work as of recent. 

Alright, I got to spend another day working on the moped. Today we installed the rear brake cable and made the seat.

Punch Starter Hole

Drill

Cut

Done

Wood

Sand curve to go over tank

More Sanding

Measure to cut for clearing of stock tank mount

router out area

Done 

Marked Mounting Holes

Drill Holes

Hammer Tee Nuts?

Done

Bolts & Rubber Washer

Cut Seat Length

Shape Seat

More Shaping

Light Sanding

Bevel Edges

Done
Staining Required

Frame Update

I installed the forks and swing arm. I will post more pictures of the fork installation once I find my pictures.
The right hand image is a picture of my future brake light that i got from www.superbrightleds.com.

Installing Engine Internals

I finally decided it was time to start putting stuff in the casing. w00t!

Giving the e50 one more bath before I put it to work. 

Next, I'm going to seal it up today and start the installation of the top end. 

Adding Area For Gasket

We didn't trust that there was enough area available for the gasket to make a good seal where the engine and the cylinder meet. So Bill thought it would be a good idea to add some area to the engine with some J-B Weld. So what the hell it couldn't hurt right.  Here we go.

Bill prepping the weld

We taped off all of the areas we didn't want the weld to get on
and put a piece of tape between the two case halves to prevent
the case from sticking together.

Cutting off the excess with a razor blade

Some soft filing to make flush. 

After we finished the next day I was organizing my work area and realized a piece of the weld came off :(

I think it was due to the very old JB "kwik" weld we used. 

I had to rip the top off to get it open :)

So the next day I went back to Auto Zone and picked up the J-B Weld Stik and redid the side that fell off. 

It worked great, no need to tape anything off. 

Side finished with the stick

Port Matching (Fix)

After visiting the Moped Army, I was told my best bet would be to J-B Weld the hole I created. So I went out and bought some "slow" curring J-B Weld and gave it a shot. 

I used heat shrink to fill in the screw hole trying to prevent the weld from
seeping into the hole. It ended up working really well.

After it dried over night, we scored the weld down the middle and it cracked it open with out a fuss.

Other side

Afterwards i did some more sanding and called it a day.
I hope it holds.

Port Matching e50

I want to start out by saying I know it's not perfect but once i went too deep on one side I didn't want to push my luck, I figured this is better than nothing.
This is for a "Cheapo 70cc Cylinder Kit" from www.1977mopeds.com

Install the gasket to mark the area that needs removed.

My markings with the gasket and studs removed

Some of the tools I used. 

The Bad Side
This is where it all went wrong. I guess the gasket outline
method isn't always the best. It looked like i had plenty of
room but I guess I was wrong. I stopped as soon as this
happened. Then I made a visit to the Moped Army to see
what my options were.

The First Side
It went pretty well I did smooth it out a bit more
afterthis picturewas taken.  I used a file and
sand paper for that. 

Main Gear Bearings

All went as planned, took off the old bearings with my puller and pressed the new ones on. 

Pulling off old bearings

Image of bare shaft

Installed snap ring

Image of both bearings installed, I used a press for the one on the right and
 a rubber malled  for the one of the left.

Painted sprockets and brake assembly

I painted my rear wheel sprocket, brake assembly and my engine gear sprocket. 

I'm going to reassemble the rear wheel tomorrow after the paint has had time to completely dry

I'm sure it's not going to last long but it's worth a shot.