Honda Elite engine/running gear into 1952 Sears Allstate scooter.

[TOOLS1]

Well it is a Honda single. I am installing a 1984 Honda Elite scooter engine and drive, along with the front wheel into a 1952 Sears Allstate Scooter. And then I am going to mount a matching sidecar.
Before






And the donor scooter


TOOLS

[TOOLS1]

Some pictures of the disassembly.


Notice that this engine runs backwards.



TOOLS

[TOOLS1]

First thing I needed to do was to mount the front wheel off the Elite scooter to establish ride height. The Elite wheel was a larger diameter, so I had to make new trailing links that lowered the wheel for clearance, and work with the Elite axle and brake.









TOOLS

[Maz]

Looking forward to  watching your progress on this,  Tools.  Those scooters are as ugly as sin,  but so gorgeous at the same time.  Your mods should transform it into a highly useable head turner. Keep the pictures coming.
Maz

[TOOLS1]

A little more done. I cut the old engine mounts/cross members out and replaced them with a piece of 2"X3" rectangular tubing. This will be the new engine mount and where the side car mount will be.


The engine/drive unit were too wide to fit in between the frame rails, so I cut them off. Now to build new ones.



TOOLS

[Maz]

Tools,  I assume you have to have the finished bike inspected by someone before it can be registered or used on the road? Over here it would need a Special Vehicle Approval inspection first and then we'd be at the mercy of the DVLA (kind of like your DMV,  I guess) and they would probably issue a non age-related plate,  beginning with the letter Q,  to show that it was made from more than one vehicle of different ages.
Maz

[TOOLS1]

Nope, none of that here. It will just keep it's antique plate. Revolution can be a good thing. 
TOOLS

[Maz]

I'm not jealous at all!
I so enjoy jumping through the government's hoops!
Maz

[TOOLS1]

On another forum, I read a post from a member in some country overseas somewhere that said they cannot make any changes to a vehicle, even tires, unless an engineer approved the changes before they were made. And the back of a motorcycle had to be white with a freakishly large taillight. After reading that, I was just soooo glad I live in the USA.
TOOLS  
P.S. However you guys do have Billie Piper, and Eve Myles.

[Maz]

Ahhh,  yes. Billie Piper.  And I thought it was just me who went weak at the knees in her presence! And Eve Myles... Strictly speaking she's  not English..... Comes from a town in Wales that can only be pronounced if you are suffering from heavy phlegm due to a bad cold!  However,  I would welcome her with open arms!
Maz

[TOOLS1]

So, is that something like the relationship between the US and Porto Rico? I am looking forward to Jodi Whittaker as the new Doctor.
TOOLS

[Maz]

Thankfully there are no 'hard' borders in the UK, so we are able to move throughout the tiny island as we wish.. Although if you use the Severn Bridge to cross the River Severn from England into Wales, you have to pay, but you don't have to pay to come the other way!
As for Dr Who,  I stopped watching it after Tom Baker! I never thought I would see a female Dr though - I may have to start watching again.
Maz

[shinyribs]

Now this is cool!

Pretty curious to see what you do with the sidecar. Will the sidecar wheel have it's own engine, too?  Just curious how much weight this thing could move around reasonably.

[TOOLS1]

Progress has been made. I mocked up the new frame pieces in wood.


I cut the frame pieces from 1" X 2" 11gauge tubing. I also made some inserts for the motor mounts, so that they would not crush the tubing.







I also made shock mounts.


I then made up a small welding table with an adjustable piece to set the angles with.


It worked great for tacking the frame rails together.


I then made a jig off the frame to line up the engine, and shock mounts.






TOOLS

[shinyribs]

Good stuff, man.

I wish this forum had the option to like/ hi five/ thumbs up a post or something. Then I remembered we have these:

[TOOLS1]

I like those.
TOOLS

[TOOLS1]

I had some time and was able to get some more done on the scooter.
I test fitted the engine on the new frame section.








Then I test fitted it on the scooter, and squared it up.






Then I added gussets and finished the welding. Being very careful not to let it warp.




However it did warp, so back to square one which was actually my first plan on how to build this frame section. I decided to make the motor mounts separate from the frame section, and then add the frame section. I ended up cutting a section out of each frame tube.




Then I made new motor mounts.


And welded them in place.




Then I fitted the frame section over the new mounts and squared it up.












TOOLS

[Maz]

Hey,  Tools.  Is there no end to your ingenuity.
I wish I had half of your skills..... and maybe a workshop the same size!
I'm so looking forward to the end result.
Maz

[TOOLS1]

Don't wish for a workshop the size of mine, wish for one at least 10 times the size of mine. I only have a 1 1/2 car garage. I have to make several trips to the basement for parts, tools...
TOOLS

[Maz]

I only have a single car garage....with all 5 bikes in it!


Maz