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Old 06-26-2013, 09:41 AM   #1
klm4755 OP
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Spare tire carrier for the Vespa GTS step-by-step walk thru

Enclosed is a step-by-step walk thru outlining the fabrication and process for installation of a spare tire on a Vespa GTS 250ie. Note that the Vespa GTS rims are interchangeable. It is OEM recommended that the rear tire (130-70/12) be slightly larger than the front tire (12070-12), but a rear wheel/tire combo can be installed on the front hub without issue. Therefore, if you are to carry a spare wheel tire it is recommended to carry the rear tire size on the spare. The thread will be separated into 5 parts:
1. Spare tire placement options
2. Attach bracket Mock-up and proof of concept
3. Bracket fabrication
4. Wheel installation
5. Horn relocation. Guess where the wheel will be mounted?
6. Review and observations


wheel placement option 1, in wheel well...loose quite abit of storage and foot placement


wheel placement option 2, on rear rack, loose aft storage


wheel placement option 3, upright on rear rack, not ascetically pleasing, would need to fabricate a bracket to mount


wheel placement option 4, on scooter side---like a pannier this would occupy the space of a pannier as pannier space is more valuable and would make the bike asymmetric.

wheel placement option 5, front faring mount. This location provides a few challenges. The challenges include:
1. clearance with front wheel faring
2. wheel attachment to scooter
3. Horn relocation
4. loss of front load carrying capability
5. headlight visability


headlight is partially blocked, I'll need to "rake" the wheel as to limit headlight beam blockage


will mount on OEM front rack


disassemble rack, won't need these parts


re-install rack


quick wheel fit check, wheel contacts post


trim post, need to tuck wheel as close as possible to scooter


make bracket from aluminum rectangle bar stock


fit about here


drill oversized hole matching the front bracket


trim attach flanges


light deburr all mounting holes


rough machined bracket, repeat process


break edges with deburr tool


add loop adhesive velcro to the bracket to front rack contact/touch points as to spare the finish of the front rack


mount check


wheel base-plate out of wood first, then metal


trim with band saw


wheel check


attach base-mount to bracket interface to front rack


attach to scooter


mount wheel to baseplate


scooter fit check


no front fender contact


still some headlight blockage, need to rake the wheel and will try another mount approach


vespa GTS front wheel hub ($30 from e-bay)


opposite side of hub, these hole attach to your front brake disc


need to trim off small tabs to make a flush surface, easy-peasy as hub is aluminum


trimmed hub


trim down the large disc to accept the hub


remove front decorative trim as the tire will tuck to a lower position, plug holes with fastener


aluminum sheet stock, 6061-T4 .125 inch gage


outline transfer from wood to metal


blend corners at 1.5 inch radii


cut on band saw


deburr


mount on bracket


mount assembly on rack


prime (2x coats) + paint (2x coats) the wheel hub


mount assembly on scooter


front view, notice the assembly blocks the horn and running light


countersink fasteners


attach hub with course thread M6 fastener, use blue loctite paste


fit check, no tire contact with scooter or bracket, only hub


front fender check, no issues


view from top


remove stebel horn from cavity. Stable horn install can be found here:
[topic114292]


will mount the horn here


need additional hose and elbow hose couplers


bond straight coupler into stebel nozzle


mount with fastener here


straight connecter bonded in horn hole


thread nozzle hole thru bracket


horn as attached


horn/hose backside view


assembly on scooter


assembly front view


need to thread horn hose thru plastic trim, no real other option


connect horn hose with hose elbow connector, easy to disconnect if assembly needs to be removed


horn mounted


wheel clearance to top of front fender


front 1/4 view, closer tucked wheel, no headlight blockage


outside front view


side view


front 1/4 view


horn mount side view


horn front view


headlight view from ground

Mod review and observations:
1. Additional piece of mind if need to conduct fix a flat where plug is insufficient
2. Certainly will mount for any long distance riding
3. No additional noise at hi-way speeds
4. Stebel horn is perceived to be ~30% louder, from re-location
5. assembly weight ~ 20 lbs, this will have benefit in cross wind conditions
6. some increase in front impact crash worthiness
7. benefit to other vespa riders if touring with GTS scooters
Enjoy!
Keithm
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Old 06-26-2013, 09:53 AM   #2
JerseyBiker
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Outstanding!!

This would have been great to have on my last Vespa. Once I added a top case in the rear the scoot developed a front tire wobble - I'm guessing due to the weight being so far back. This weight in the front might have cancelled out the wobble.

In any event, an absolute fantastic job and terrific step by step instructions!

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Old 06-26-2013, 12:38 PM   #3
rpclark
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Will it fit on the back?
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Old 06-26-2013, 12:49 PM   #4
gogogordy
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Well done!

As usual Keith very well done farkle.

I'd make 2 suggestions:

1) Protective "clear bra" circles on the paint, under the rubber cups

2) Your voltage regulator's already minimal airflow has just been reduced even further...they get plenty hot in normal use with just the small amount of airflow the horncast allows in. On my GTS, I drilled several air holes in the plastic shroud the VR mounts above, on the throttle side radiator. Can't hurt and did I mention that VR gets hot as hell?
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Old 06-26-2013, 01:18 PM   #5
klm4755 OP
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Quote:
Originally Posted by gogogordy View Post
As usual Keith very well done farkle.

I'd make 2 suggestions:

1) Protective "clear bra" circles on the paint, under the rubber cups

2) Your voltage regulator's already minimal airflow has just been reduced even further...they get plenty hot in normal use with just the small amount of airflow the horncast allows in. On my GTS, I drilled several air holes in the plastic shroud the VR mounts above, on the throttle side radiator. Can't hurt and did I mention that VR gets hot as hell?
Good comments, I'll take alook at directing some flow to the cavity, unaware the cavity usage was for VR cooling. I'll also need to add aux front turn signals as the tire/wheel blocks view from head on.
Keithm
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Old 06-26-2013, 01:19 PM   #6
klm4755 OP
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Originally Posted by rpclark View Post
Will it fit on the back?
Yes, the wheel would fit on the back rack, but at the loss of the racks cargo carry ability.
Keithm
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Old 06-26-2013, 01:32 PM   #7
gogogordy
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Quote:
Originally Posted by klm4755 View Post
Good comments, I'll take alook at directing some flow to the cavity, unaware the cavity usage was for VR cooling. I'll also need to add aux front turn signals as the tire/wheel blocks view from head on.
Keithm
The VR lives on top of the black plastic right-side radiator shroud and gets very little cooling air.

I'm certain you know how much electonics like heat...and Im not saying the VR wouldnt fail otherwise, but on the Vespas they are buried so uncharacteristically deep when compared to most other PTW's I dont see a down side to adding some cooling.

Anyway...great mod (I mounted my Rotopax up front in a similar fashion) and very well executed and documented. thanks for sharing.
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Old 06-26-2013, 01:33 PM   #8
gogogordy
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Quote:
Originally Posted by klm4755 View Post
Yes, the wheel would fit on the back rack, but at the loss of the racks cargo carry ability.
Keithm
Add'l benefit: The add'l weight up front from my gas or your spare actually improves the ride and handling/braking IMO.
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Old 06-28-2013, 01:16 AM   #9
conchscooter
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Thats a very clever and well thought out piece of work. From my own experience with a GTS removing the rear wheel is unnecessarily complicated and difficult- dealing with the exhaust and the fragile bushing (I used the Moto Amore bushing which I'm told also crumbles after a while) and the impossible to move bearing in the support plate for the wheel. I loved riding the GTS but the original vespa concept of simplicity seemed to have got left behind on these four stroke machines.
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Old 06-29-2013, 08:22 PM   #10
Warney
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Excellent fabricating skills and a clever solution. Changing a rear tire on the side of the road on a Vespa GTS is impossible without pliers, a breaker bar, multiple sockets, hex bit socket, torx bit socket, a socket wrench, extensions, and a torque wrench. Who carries all that? Then there is the matter of that fragile graphite bearing...

Vespaman video
http://www.youtube.com/watch?v=eUNXDSvpN7I
Alternate method requiring even more tools
http://www.youtube.com/watch?v=iSvFcNRFEuM
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Old 06-30-2013, 07:39 AM   #11
klm4755 OP
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Quote:
Originally Posted by Warney View Post
Excellent fabricating skills and a clever solution. Changing a rear tire on the side of the road on a Vespa GTS is impossible without pliers, a breaker bar, multiple sockets, hex bit socket, torx bit socket, a socket wrench, extensions, and a torque wrench. Who carries all that? Then there is the matter of that fragile graphite bearing...

Vespaman video
http://www.youtube.com/watch?v=eUNXDSvpN7I
Alternate method requiring even more tools
http://www.youtube.com/watch?v=iSvFcNRFEuM
Good point, I'd suspect it would be desirable to carry these tools while in touring mode. I'm in the process of fabricating a lockable metal pannier for storage. Here are a couple of shots of concept:

pannier rack

rack + metal ammo can

left side of scooter, not yet fabricated rack to can mount....

I plan on carrying the tool list listed within the pannier.
Keithm
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