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 kayakbuilder's '99 budget (re-)build 
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Post Re: kayakbuilder's '99 budget (re-)build
Yeah that looks nice. your scooter is going to look sculpted.


Sat Jul 07, 2012 1:30 pm
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Post Re: kayakbuilder's '99 budget (re-)build
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Trying to decide what to do with the textured area of the main body panel. I don't think the hammered paint will work well on the textured area, so I may mask it off and coat it with black bedliner paint.

I've got the main body panel ready for primer. Sanded the scratches out, wet sanded, rinsed, washed with mineral spirits, washed with simple green, wet sanded again, washed with simple green again, and thoroughly rinsed.

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Sat Jul 07, 2012 9:35 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Got the main body panel (side cover) painted.
Image

Now I am prepping the belly pan for fixing the hole and painting with bedliner.
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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Mon Jul 09, 2012 8:03 pm
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Post Re: kayakbuilder's '99 budget (re-)build
daex wrote:
Yeah that looks nice. your scooter is going to look sculpted.


I probably could have gotten the fairing straighter by sculpting a new one. :haw:

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Tue Jul 10, 2012 5:36 pm
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Post Re: kayakbuilder's '99 budget (re-)build
All of the breaks and cracks have repaired nicely and feel strong, except this one at the top of the leg shield. I don't know if it is because it is a different harder plastic, or if something has contaminated the surface, but every time I think I have a good weld it cracks open again while cleaning it up. Not sure how best to solve this one. I want it done and painted already!
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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Sat Jul 14, 2012 10:54 pm
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Post Re: kayakbuilder's '99 budget (re-)build
The bedliner paint wasn't adhering well to the plastic, so I have switched to Plasti Dip for all of the black panels (belly pan, leg shield, access cover, over fender, cowling, and footrest). I don't want too much of the hammered paint.

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Sun Jul 15, 2012 11:31 am
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Post Re: kayakbuilder's '99 budget (re-)build
Finally got a repair on the leg shield that held. I had to push the hot knife deep into the crack from both sides, the usmooth the melted plastic back into the crack. It is all puttied and sanded. Not it is ready for paint!
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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Sun Jul 15, 2012 4:35 pm
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Post Re: kayakbuilder's '99 budget (re-)build
The painting of the footrest and leg shield came out great. The leg shield would have been better if I had really worked on the bodywork more, smoothing out the imperfections.
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_________________
2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Mon Jul 16, 2012 11:54 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Ok the Plastic welding is awesome. i may be able to save a good chunk of money on my plastics now.

even better the paint is awesome!!

My Bug Eye was given to me to xD

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Tue Jul 17, 2012 12:51 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Cleaned the carb and bumped it up to a 98 main jet.

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_________________
2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Tue Jul 24, 2012 8:28 pm
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Post Re: kayakbuilder's '99 budget (re-)build
ratch wrote:
Ok the Plastic welding is awesome. i may be able to save a good chunk of money on my plastics now.

even better the paint is awesome!!

My Bug Eye was given to me to xD


Thanks Ratch,

I finally got it all back together. Problem it the fairing was so mangled, and the brackets were bent. One of the repairs on the fender cracked because it didn't quite fit right. Looks like more repairs are needed, but I may look for another fairing. Aside from the crack, I like the way it is looking. I still need to put the varitator back together, finish hooking up the carb, put fresh gas in, and wait for the battery to finish charging up.

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_________________
2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Tue Jul 24, 2012 8:51 pm
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Post Re: kayakbuilder's '99 budget (re-)build
After draining the tank yesterday, I put in one gallon of fresh premium treated with one oz of Seafoam.

Looks like I need a new float bowl gasket. I sucked on the vaccum line to prime the float bowl, and now it is leaking gas at the low end of the top of the bowl.

I also seem to be missing one slider that goes on the variator cam plate, and one of the little silver weights from the starter clutch. I haven't tried to put the airbox back on yet, and expect it to be a pain since it is old and has been off for so long.

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Wed Jul 25, 2012 5:35 pm
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Post Re: kayakbuilder's '99 budget (re-)build
I found the missing slider for the variator cam plate. I will probably just pull the springs and weights out of the starter clutch for now. I am debating on buying a rebuild kit to get the carb gasket, or just buy a 17.5 or 19 Dellorto.

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Last edited by kayakbuilder on Tue Aug 14, 2012 6:34 pm, edited 1 time in total.



Thu Jul 26, 2012 4:38 pm
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Post Re: kayakbuilder's '99 budget (re-)build
I can feel the fun. looks good.


Sat Jul 28, 2012 5:40 am
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Post Re: kayakbuilder's '99 budget (re-)build
Waiting for more than 2 weeks for the new carb from Dellorto Direct. They haven't shipped it yet!

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Tue Aug 14, 2012 6:36 pm
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