New and improved!

Having not updated the site for a couple of weeks (due to holiday) – I thought I would continue with an update on the front end. After ordering a bunch of parts from allstyles-scooters I finally got all the bits I needed to reconstruct and restore the steering column, fork and front hub.

With the front column de constructed I started restoration of the main column, sanding it down to remove any sign of rust and crud back to the bare metal, with as lick of primer and silver hamerite it was looking a hell of a lot better than its previous state. Leaving that to dry I set my sights on the lower hub assembly. With all the new pins, roller bearings, washers, springs and damper set out in front of me I began to arrange the parts in order referencing the exploded parts diagram from the VNB parts PDF file (which can be downloaded here).

After the main column had dried I began by inserting the new roller pin bearings which the main pivot pin would be inserted into. The insertion of the various pins and lower shock bracket took a little messing around, taking out and re-inserting with various washers and shims to get the perfect fit, without it being too tight or too loose with any side to side slack, specifically the lower spring bracket. After trying countless configurations I came to the conclusion that the new bracket was a fraction wider than the original which was causing my “tight” problems, so with some course sandpaper I thinned it down slightly until the bracket could move smoothly on the pin.

With the lower assembly now pivoting on the column, and the lower spring bracket installed, it was time to get the spring and damper on – begin the hours of head scratching.

The obvious problem with the spring is that it seemed way too long, after speak with gary and allstyles he explained that it is the shortest spring they supply, however could still be too long and may require a ring or two cutting off the spring, so thats exactly what I did – cutting it down to meet the length of the old original spring – but alas, it was still too long. I couldnt see any way in which the top of the spring could be negotiated to fit into the top bracket without it being compressed first, and the released once in position.

After countless attempts to compress the spring with large sash cramps, string, cable ties and all manor of crazy inventions, nothing was working and I was beginning get a little dispondant holding this lovely shiny spring in my hand. So I enrolled the help of my friend Lel as I figured another brain and pair of hands would at least get me nearer to my goal.

After half an hour of trying different techniques, we both came to the conclusion that brute force was the key and by bending the spring down toward where the top bolt would sit, we used a large screwdriver and a hell of a lot of pressure to bend the spring down into place. With a final big whack with a wooden mallet the spring top bolt popped through the whole with a satisfying “PANG”!

Phew…. the relief.

Newly polished steering column

Holding the steering column upright and resting the lower assembly on the floor I was able to put my foot on the top spring arm and press down to compress the spring, allow the damper bottom whole to line up with the bottom assembly. Lel slid the bolt through and tightened it – Success!

With the front now back together as one unit, I was happy with my work, although there are still a few minor bits and bobs to finish on the assembly (grease the pins, install the break actuator), it is 99% complete -one project down….. millions to go.