Every time I go to start a project on this scooter I end up having to buy more parts!

This time around it was primarily the headset area that I started with as after further inspection of the bulb housing it turned out that the one that I had was for an SX/TV & they are different shapes.

Actually an aside, the quality was surprisingly very good even though it was Vietnamese copy, it was just for the wrong model & had been hacked to fir the Li headset.

I also needed the actually bulb holder and a few other bits, so it was off to the Scooter Restorations website & yet another two part order that turned into a 15 parts order!

I ended up getting a complete set of floorboard runners + a heap of other little parts.

The two major items were the Series 3 CEV Head Light Bulb Holder & LI Series 3 Headlight Unit (Marked Innocenti CEV), even though these are reproductions they are the correct items that would have been on the scooter when it rolled out of the Innocenti factory 48 years ago.

Headlight unit & all the little parts

Floor set, looks like I have some polishing to do before installation!

So I finally got my second set of forks back from the painter as the original forks had a kink in them and they would not turn completly, that set will have to go off to be repaired/straightend for a later project.

I had damper mounts welded onto this set before they were painted making it easier to fit the extra suspension parts.

I cleaned up all the internals with the new benchtop sandblasting cabinet I bought recently and also cleaned up the fork links by blasting them with household grade bicarb sode, they can up a treat & it was worth the 30mins it took.

Internal parts before sandblasting:

Internal parts after sandblasting:

Forks all taped up for rebuild:

New Buffers

In go the springs.

Fork spring compressing tool in action, bloody thing scrrated the paint work even through the tape!

Buffers installed

All done, satisfied but as usual a little frustrated as its my first go at this.

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Up next: 

1. Refit to scooter
2. Fit front hub
3. Fit Dampers

The balance of my stainless steel parts order arrived late last week so I was able to get the parts onto the engine and do a test fit.

• Changed the mag plate from the original one as it was to far gone with surface rust with a Mag Housing Seal Kit 
• Replaced the Breather cap as it was shot
• Replaced Front & Rear Brake Adjusters, although I retained the original brass knobs
• Added a new Gear Adjuster Block Cable Clamp as the old one was bent out out preportions
• Grabbed a new 6-12volt AC Horn as the old was was a mess, also need a new mounting bracket as the original is too rusty.

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Test fitted the carb as well, starting to take shape now.

Old & new mag plates, its the little things that make a difference.

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Jobs for next weekend!

• Headset
  • Do some felting with the ignition switch housing so it sits deeper for a better fit
  • Order an original CEV or Carello headlight bulb housing for headset
  • Fit steering lock
• Engine Bay
  • Refit petrol tank & replace the rubbers with new ones
• Front Forks & HubRebuild & refit new forks with dampner mounts
  • Check front hubs brake shoe clearance

Option Three – “Original look” Spare wheel carrier

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Bit boring, but if you wanted a more original look this is it.

Not 100% sure if this is a Series 3 accessory though, but it is a 100% original Italian part, need to look into this more.

Option Two – Sprint Rack

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Looks good but its not fitting too well, might need some fetling to get it in 100%.

Option One – Rear Carrier with Spare wheel holder & back rest for pillion rider.

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If I go with this option then I will be buying the pad on the back rest to match the seat.

Few catch up posts tonight & this is the test fitting of the hub onto the forks.[[posterous-content:pid___0]][[posterous-content:pid___1]][[posterous-content:pid___2]]