Puch Magnum Build

Update about the images

2015-06-02T16:31:00.000-04:00

Due to a domain change none of my images are working anymore and instead of trying to reupload all of them i'm going to share a link to the full gallery of images from the project. If you have any questions concerning this please feel free to contact me.

Link To Gallery

Petit Lemans Trip 2013 Pictures

2013-10-21T15:22:00.002-04:00

Pictures from this year during Petit Lemans 2013 at Road Atlanta.

The Magnum's First Trip Out

2012-10-24T13:22:00.002-04:00

Well I took the magnum out of the neighborhood, I made a recent visit to Petit Lemans and thought it would make a great bike to get around the track.

Everything went okay with the moped, but on the first day the clutch started to stick for some reason. The hills at the track are crazy and when I stopped at the bottom of the hill and tried to make it up the hill the bike didn't like it very much. Once i figured that out, I just made sure I kept my momentum up and it did fine the rest of the week.

Of course i still have things that need to be done to get it to 100% but it was fun to actually take it out and show her off a bit even though I did get a little annoyed with the dozen's of people asking what it was.

My current problem is the top speed, it seems to be topping out at 35 mph and feels like it's missing.

Hopefully it's just the timing or something.

Below are some pictures of it at the track.

and here is link to some pictures I took.

Race Gallery

More Progress but not 100% complete

2012-04-16T11:04:00.000-04:00

I got a chance to work on the moped again, I didn't take too many pictures this time, but here is a list of things I finished up.

Installed clutch engagement lever correctly.
License plate mount (pics to come)
Re-installed tank and seat after paint jobs.
Adjusted brakes (still doesn't stop worth a crap)
Wired Headlight
Took it for a ride and successfully bump started it. (next cold bump start)

Thing to do:

Buy and figure out how to wire my regulator to get my lights working.
Install brake/tail light and run brake light wire.
Paint intake, tank mounting hardware, and license plate mount.
Cut and stain pegs
....

Brake Cable Thingy & Seat Creation

2012-02-20T00:00:00.002-05:00

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

The Magnum Roars!

2012-02-07T13:05:00.000-05:00

The magnum finally took it's first breath and created fire and smoke. Tonight was the very first time this engine has turned over and all went better than expected. I still have a lot to do before I can call it finished but it's great motivation hearing it run for the first time.

Other stuff done last night (spark plug boot, fuel line, grounded, added transmission fluid, a few other thing)

Custom Exhaust Bracket

2012-02-07T12:57:00.001-05:00

Using the old left over piece of the L bracket from the tank mounting hardware, a exhaust bracket was born.

Pound It

Grind It

Yay Sparks!

Be amazed that it lines up and tighten.

This design might be reworked, we talked about using some square pipe but for now this will work.

Chain Adjusters

2012-02-07T10:24:00.000-05:00

Well it is now time to install the chain adjusters. The only problem is, I only have chain adjusters for a Maxi. So what do we do next; Fab them. I'm going to use the eye bolt from the Maxi adjusters and make the back brackets.

Square Tubing

A Little Sanding

Hole Punch

Drilling

Cutting

Splitting

Rough Cuts

Smoothing

More Sanding

The Finished Product

Painted and Installed

Seat (alpha)

2012-01-19T11:21:00.001-05:00

Bought some nice wood for my seat, this is the alpha build of it. :)
I'm going to cut,shape, and stain it.

Custom Gas Tank Mount

2012-01-19T11:16:00.000-05:00

To begin, Bill and I had to ponder the millions of ways we could possibly mount this tank on to the frame. After hours of major brainstorming this is what we came up with.

Foam Spacer

Cutting

Fitting

Done

Creating the brackets

Drilling

Cutting

Resting

Grinding

Sanding

Showing Off

Fitting The Top Mount

Parts

Measuring

Cutting

Fitting

Mark up

Measuring

Parts II

Pre-Cut

Cut

Sanding

Assembling

Assembling II

Showing Off

Cutting

Fitting

Cutting

Spacers

Fitting

Done

How She Sits Now

The tank and brackets will be painted black before final assembly.

A little Progress (intake/carb installed)

2011-12-31T14:29:00.000-05:00

Well I finally got around to working on the moped again, not much but i have moved it right next to my TV hoping to motivate me to get this damn thing finished. Today I went to Home Depot and bought a dishwasher hose and a clamp, cut the hose to size and mounted the carb.

Up next find a damn bolt that will fit the muffler. I thought it was a m6 but it they only seem to screw in a few threads. This is how it sits now.

Custom Intake Manifold

2011-04-04T10:54:00.000-04:00

Trace Your Gasket

Drill Your Bolt Holes

File Your Port

Notice The Square to Circle Transition

Old Motorcycle Bars

Make Your Cut

Perfect Intake

Handlebar Carnage

Confirm Clearance

Begin Your Weld

Wooded Jig To Line Up Ports

Begin to Grind

And File

Confirm Bolt Placement

Grassroot Art Work

Tail/Brake light mount

2011-01-24T19:18:00.000-05:00

I've been looking for a pipe that would fit perfectly in the tail end of the frame, but I haven't had much luck with that. This piece is pretty close. When mounted in the frame, I should be able to unscrew the light and keep the base in place. I'm thinking I will use hot glue to secure the pipe in the end of the frame. I"ll make and update once i get it mounted. I"m hoping sometime in the future to find a metal pipe so i can use some jb weld to mount it in the frame.

Brake Light Wiring

2011-01-24T19:00:00.000-05:00

I started by drilling two/three holes into my frame. I say three because there is two layers you have to drill through on the top bar of the frame. I used a vacuum to pull a thread through the frame, then i tied 2 fishing lines to the string and pulled that through. I used two lines instead of one because my holes weren't big enough to run them both at the same time. Over all it was a PIA but i think it's going to be well worth it in the end, but I have decided to not run the wires going to the front forks in the frame. (by the way, the wire does run out the back for my tail/brake light)

A Little Progress

2010-12-31T12:23:00.000-05:00

Over the last month I didn't get as much done as I would have liked, but between getting sick and the holidays time just flew by. My new site Mopeds 101 has been taking up some of my time also (thank you to everyone that has joined the forum). Ok, back to the Magnum.

I received my tank in, it's not a magnum tank but with a little modification it should work pretty well.

I also installed the cylinder and head, I don't have pictures of the actually process. I can only do so much with two hands :).

Image of the my stator plate with the brown wire moved to the top of the plate instead of the bottom. I also used a dremmel cut off the extra length the screw had on the bottom.

Oh yea, my wife wanted her dinning room table back so I moved my operation into my office.

I also tried to hook up my brake cables, but the front seems to be too short and the back is doing something funky. I got pretty frustrated so I moved on to something else. I also picked up some parts to assemble my tail light. I'll have pictures of that soon.

Partial Assembly

2010-11-17T13:15:00.000-05:00

After I reassembled the forks I couldn't resist to do a little mock assembly. I'm going to tear it back down to drill the holes in the frame to run the wiring and cables, but here is a peek of it's stance.

Fork Lube Job

2010-11-17T13:10:00.001-05:00

First I cleaned the bushings and unscrewed the fork springs, then I scrubbed the springs down in my trusty trash can of gasoline. (it was full when the project started)

Then I gave everything a good lube job, I wasn't sure what I should grease so I greased everything.

Below I reinstalled the bushings and dust cap on the forks then screwed the springs back into the fork arms.

Friendly Tip Below

PUT YOUR BUSHINGS AND CAP ON BEFORE YOU SCREW THE SPRING IN

Frame Update

2010-11-12T11:41:00.001-05:00

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.

Mounted Tires

2010-11-12T10:42:00.000-05:00

Mounted the tires, all went as planned and i'm happy with the results.

Handlebars and Controls

2010-11-12T10:34:00.001-05:00

I painted my 19 mm intake I purchased (thanx orangerobin) on www.Mopedarmy.com and painted my handlebar clamps, then I installed the controls and replaced the grips with some Kawasaki grips a friend gave me. They seem to be much better than the ones that came with the controls. I was a little disappointed that there wasn't a brake light switch holder :(. Now i'm on the hunt for some new M7x35 socket cap bolts to mount the handle bars. This is what my current ones look like, I'll clean them up and use them if i have to.

I also have to give www.TreatLand.tv a big thank you for having such great customer service, I would highly recommend them to anyone building a moped.

Order New Part (Thanx Google)

2010-10-31T10:50:00.003-04:00

Since i finally got my Google check, i decided it was time to buy some more parts.
I ordered this batch from Treat Land, the descriptions of the products on the site
crack me up. (you should check them out)
I've always had great service with them and 1977 Mopeds it just all depends on
who has what in stock.
let the list begin. :)

bikemaster black superbike low rise handlebars

lusito complete throttle control set - black

moped rear brake cable

moped front brake cable

moped throttle cable for all mopeds

puch moped one speed E50 clutch cable

puch BLUE hi tension E50 clutch spring

more expensive moped inner tube

rubber rim strip

I also ordered an intake for my carb, that should be in around the same time.

w00t!

Installing Engine Internals

2010-10-25T13:03:00.002-04:00

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

2010-10-25T12:53:00.002-04:00

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)

2010-10-25T12:16:00.004-04:00

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

2010-10-25T11:53:00.004-04:00

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.