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Although most of our work is the design and construction of bespoke and one-off fabrications and projects for our customers We have yet to have a page dedicated to this. This is a work in progress and will be updated as we build these projects. Currently under construction.
Lambretta Auto Conversion Project This will be a step by step pictorial on the way we build an auto-conversion. There are no trade secrets here just a lot of hard work,design and fabrication. This is how it starts. First get your Lambretta chassis and an automatic 172 Piaggio engine (this engine is a jig and not the completed engine, pictures of the work involved in that will follow) and remove the major part of the chassis and structure, insert the engine approximately then using a variety of tools such as laser pens,spirit levels and engineers squares ensure things such as the ride height and cowling clearances are correct and everything is square on to the chassis. The bottom part of the engine mount completed and welded to a substantial piece of box section that is in turn welded to the chassis. This section is the start and the rest of the bottom mount branches from there. The two main arms are constructed to use Vespa PX engine bushes and then braced using smaller diameter tubing.
Welding the rear suspension mount in place. To the rear suspension mount the rear subframe brace is then welded. This supports the rear of the frame. The whole assembly is welded to the inside of the rear frame as well as being further braced by a welded steel plate underneath. The rear runner tubes will then be welded to this subframe connecting the front engine mounts to this making the whole structure rigid. The completed framework. The previous two fabrications (front engine mounts and the rear subframe/rear shock mount) have now been mated together with the two side runners. These are fabricated out of 3mm wall thickness steel tube and formed into shape on a 12 tonne hydraulic pipe bender. By using a donor engine as a jig for the frame construction we are free to work on the actual engine for the project. This is still waiting for the genuine engine mount bushes to be fitted but has been stripped, matched and gas flowed for better performance.
The completed rolling chassis. A closer view showing the runners with bottom reinforcing gussets on the engine mounts. Work now starts on designing and fabricating a one-off fuel tank to fit between the runners giving the maximum fuel capacity possible plus all the ancillery brackets for mounting the battery,coil,CDI unit,regulator etc before moving onto the wiring,cables,bodywork fittings, braking systems. There is still a lot of work involved before it`s ready for the road The battery tray supports and the battery tray completed and welded in, hooks in place to locate the rubber securing straps. The other side of the battery tray which also doubles as the ignition coil mount (the protruding studs have since been shortened to suit). The construction of the purpose built fuel tank, filler neck and fuel tap spigot are in place as is the internal reinforcement that acts as a fuel baffle to stop the fuel surging around inside. Not shown on the top is the addition of a fuel tank breather to prevent vacuum lock should the filler cap breather get blocked. Fully TIG welded up and set in place being measured up for the mounting brackets.
The finished fuel tank mounted in place shown from beneath. It is constructed out of mild steel (as the previous images show) however rather than just painting it we decided to powder coat it for more protection and durability. We used a Chromex Hi Chrome powder electrostatically applied and baked in an oven. Not quite full chrome but a stunning finish for powdercoat. The side view, in situ, you can see part of the battery tray reflected in the front of the fuel tank. Most of the major components are now in place including all the major electrical parts, fuel tank and hi-flow 90 degree fuel tap,Delorto 25mm carb, rear hugger etc. The next part of the build is the panel,legshield and rear footboard fitting to check clearances and modify as needed. There is still a long way to go on this project, the initial build has been a dry run using an identical bare engine and the engine proper has to be built, the wiring,cables,brakes and finally the exhaust system have still to be designed and fabricated/fitted.