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Old 08-08-2013, 04:13 PM   #1
klm4755 OP
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Homemade hiway pegs for vespa GTS 250 Project

Enclosed is a step-by-step walkthru outlining the fabrication of hiway pegs for a vespa GTS scooter. The intent of the hiway pegs is to provide cramped leg relief on long distance rides. Couple goals of the fabrication include:
1. No scooter frame drill
2. Minimal foot well loss when pegs in storage
3. No weld, as I have zero weld skills
4. Robust design
5. Locate pegs as to minimize no ground contact while in turns
6. removable system
7. easy on/off for scooter cleaning, maintenance and such
I ended up fabricating several concepts (mock-ups). This thread outlines iteration # 3.


Hiway pegs to mount (from e-bay at $26 USD) linky here:
http://www.ebay.com/sch/i.html?_trks...at=0&_from=R40


hiway peg packaging label


need about 3 feet of .75 inch x.75 inch square 6061 aluminum square tubing


need ~12 inch of 3M dual lock (about 5x stronger than velcro)


about 2 ft x 2 ft section of 6061-T6 aluminum sheet, t = .125 inch


mark and trim sheet splice strips


attach splice strips to square tubing


butt-up to footwell hump


strip down the pegs retaining only peg, peg bracket and attach bolt


measure bolt diameter


maintain 2 diameter edge distance on bolt thru square tubing


trim and cut splice for hiway peg square tube attach bracket


rough fit check


splices attached to square tubing


peg mounted to bracket


need to fabricate attach pads (6x total) these will fit between the footwell protruding ribs and connect the hiway peg system to the scooter


tap (thread) hole to accept a M4 course thread bolt (I ended up just using a single fastener per pad).


get out hole punch 3/16 size


punch hole in dual lock


like so


bond to pad (adhesive backing) where threaded hole is located


pads attached to bracket with fastener


attach to hiway bracket at footwell between protruding ribs


right and left side in rough stage, need to connect the two sides


fits like so....


checking upper splice connection fastener grip length size


bracket in rough state


starting to reinforce with additional fasteners and swapping the protruding head fasteners with flush head fasteners (counter-sink)


filing the edges, deburring the splices and tubes


adding a decorative top cap


mount bracket....Notice all fasteners are flush, added center top cap, filed off all excess material


bolt on hiway pegs


hiway pegs mounted


front view pegs stowed


pegs stowed offset view


first person view....pegs extended


first person view pegs in use.


1/4 scooter view pegs stowed


3/4 scooter view pegs stowed

Notes and observations:
1. difficult fabrication, several iterations to get in to work
2. completely removable
3. loose little foot area with bracket installed
4. pretty robust system. Can push hard and load is transferred into the foot well without issue. Needed to connect the 2 sides to cancel out the induced moment developed by the eccentric load formed from the foot peg load transfer.
5. Nice to be able to extend legs during long rides. works well and complements the back-rest jacket lumbar system.
Enjoy!
Keithm
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Old 08-08-2013, 06:39 PM   #2
climbamt
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Nice job Keith!
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Old 08-08-2013, 07:23 PM   #3
damasovi
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you keep on improving that vespa man!!

D.
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Old 08-09-2013, 05:09 AM   #4
hayasakiman
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Are they stainless steel hardware on aluminum?
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Old 08-09-2013, 07:32 AM   #5
klm4755 OP
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Quote:
Originally Posted by hayasakiman View Post
Are they stainless steel hardware on aluminum?
The fasteners are all stainless steel. I do not see any issues as with this combination as the area of the annode material (Aluminum) is much larger than the area of the cathode (stainless steel). There should be no dissimilar material or galvanic corrosion compatibility concerns.
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Old 08-09-2013, 07:33 AM   #6
klm4755 OP
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Here is a couple enhancement to the hiway peg bracket:


added center flush fastener, all fasteners are metric stainless steel


will finish the surface with wet sand paper at 120, 400 and 1000 grit


after 120 grit


after 400 grit


after 1,000 grit


brushed steel look


close-up of flush stainless steel fastener counter sunk head


attach tab holes


weight = 2 lbs 9.4 oz


as mounted after sanding + added fasteners


right side view


front view pegs down


close-up right peg down


close-up right peg stowed


left side peg stowed


offset view

Keithm
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Old 08-10-2013, 02:51 PM   #7
TheReaper!
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It's a good thing we're not neighbors , we would be up half the night fabricating shit .

TheReaper!
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Old 08-12-2013, 05:03 PM   #8
Shirker
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Great fab skills!

What does the underside of the floorboards look like? Would strap bars mounted below with your rig for the outboard pegs lose you significant clearance?
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Old 08-12-2013, 11:06 PM   #9
gogogordy
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Quote:
Originally Posted by TheReaper! View Post
It's a good thing we're not neighbors , we would be up half the night fabricating shit .

TheReaper!
I fab some of that daily, and get a good night's sleep while I'm manufacturing it.

Product distribution begins at 0600 daily.
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Old 08-17-2013, 05:33 PM   #10
klm4755 OP
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Quote:
Originally Posted by Shirker View Post
Great fab skills!

What does the underside of the floorboards look like? Would strap bars mounted below with your rig for the outboard pegs lose you significant clearance?
I did not desire to drill into the frame (metal part anyway). I considered an underside mount, but it would require fabrication of a curved bracket to match the outer mold line and drilling into the front metal fairing. I'm happy with the mount location, as a nice benefit, I recieve a cool breeze up the pant when in hiway pegs are in use. Probably not so nice on a cold day.
Keithm
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Old 08-23-2013, 10:09 AM   #11
Motovista
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That is really neat. I like the way it doesn't require destroying the plastics on the bike and looks like it easily comes off.
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Old 08-25-2013, 07:56 AM   #12
klm4755 OP
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Originally Posted by scooterpartsco View Post
That is really neat. I like the way it doesn't require destroying the plastics on the bike and looks like it easily comes off.
I was tempted to attach to floorboard, but the dual lock is working well. As a side note, I receive lots of airflow up the pant lag to make for a nice cool run on hot days.
Keithm
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