When starting a restoration at the Workshop, we know that it often involves a long, even very long, process.
Disassembling/reassembling a moped may seem easy at first glance, but it's far from it, and every moped, from the rarest to the most common, always holds its share of surprises, some good but often bad...
These challenges must be managed one after another; ideas and solutions must be found so that the final work is as correct as possible and the moped can hit the road for many years to come.
In short, as you've understood, "quick and good" rarely go together. 🙂
After the initial work of disassembly and inventorying missing or unserviceable parts, several tasks must be undertaken simultaneously: cleaning, stripping, sandblasting, painting, chroming, zinc plating, and researching and fabricating the pre-identified missing parts.
During these stages, it is quite common to face certain difficulties: parts needing bodywork, fasteners too corroded to be properly zinc-plated and therefore needing to be recreated, parts too rusty to be repainted, heavily corroded chrome, etc.
Added to this are potential "failures" during these stages: dull zinc plating, paint mishaps on certain parts, and so on...
After a few weeks or months, however, everything is gathered together, and we find ourselves with several boxes: a repainted frame, screws, chromed parts, parts to be treated as assembly progresses, various accessories.
And the reassembly work begins...
Remember... this AV3 arrived at the Workshop looking like this:
Disassembly, a relatively quick operation where everything is neatly organized by theme in boxes:
the engine...
the zinc plating...
the chrome...
the frame...
Little by little, all these elements are treated and restored to "new" condition.
At the same time, each part is carefully inventoried (it's essential to know where each element goes!!), which facilitates reassembly.
...then everything is carefully packaged to avoid breakage before final assembly.
When everything seems "correct" and "complete," we begin reassembly, and as we go, we resolve any problems that arise.
We start by "dressing" the frame, beginning with this:
(Admit it, the new night gray tint is more compliant than the green in the first photo. :) )
Based on this, we begin the work of tracing and creating the pinstripes if they were originally present... a long, tedious, and difficult task depending on the type of machine.
On this AV3, the pinstripes are numerous and "tortuous," so the work is not easy: pinstripes on the frame, the front and rear mudguards, the side covers, and the fuel tank.
Once the pinstripes are finished, the "decals" are applied, then, when everything is thoroughly dry (about a week), the whole is varnished to protect these decorative elements from minor aggressions, oils, and other hydrocarbons.
Then comes the installation of the fork and handlebars, just to have a mounting skeleton.
When everything is repainted and rechromed, all parts must be reworked so that everything fits together cleanly, because the layers of paint and chrome are quite thick... meticulous work every time.
For the chrome, we also try to recover the original inscriptions: here: MOBYLETTE.
It is therefore necessary to know how to polish without destroying, to measure what needs to be removed in "rust" without distorting the original piece.
Handlebar installation:
Next, we tackle the pedal assembly with the same work of assembly and adjustment:
These rechromed "Gauls" have a terrible look, I think!
At this stage, the cycle part can be "hung," which makes it easier to work all around it.
Reinstalling the mudguards... here too, innovation is key. For example, the "silent block" piece between the mudguard and the fork was remade with a 3D printer.
It's always nice to mix modernity and originality.
With the mudguards in place, we tackle the "cockpit".
The throttle and decompression grip consists of 6 rechromed parts.
The new open-ended grip and the brake lever, glass-blasted, polished and varnished.
Same for the other side
Installation of the front then rear brakes
here too, priority is given to originality and the preservation of "inscriptions"
And then the first tests of the system:
Fuel tank installation
Of the luggage rack
Reconstruction of the front headlight (not compliant with the original model) using the original model as an example:
its "parabola," from an old bicycle,
and its "Art Deco" style casing in NOS
Same for the rear, and each time, glass-blasting, polishing, and varnishing.
Almost all the fasteners were redone each time, as the old ones were really too corroded.
When rust causes too much damage to fasteners, it's impossible to have threads with proper grip for tightening, so they must be remade.
Reassembly of the saddle structure: 15 pieces in total... painted, chromed, or zinc-plated accordingly...
And first "test" on frame
and the "bungee cords" before the seat cover
Wheel reconstruction….
we start from here: a new rim, new spokes and a re-chromed hub
to arrive at this
same for the front…..
And we mount the tires
While waiting to receive certain parts that could only be ordered at this stage, we are perfecting details such as the repair of the pump or other "accessories".
and we anticipate the "engine" part.
Thus the drive teeth of the pulley were worn out: note the curvature!!
and if we still find some of these parts, the internal diameter is not identical:
it is therefore necessary to bush the new part so that the adaptation is perfect
the trick is done…
As you have understood, all this takes time and that is why I thank you for your understanding and above all for your trust.
The Workshop has only one wish: to offer its customers the best possible service for their moped.
To be continued …..