Homemade hiway pegs for vespa GTS 250 Project

Discussion in 'Battle Scooters' started by klm4755, Aug 8, 2013.

  1. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    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.

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

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    hiway peg packaging label

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

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

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

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    mark and trim sheet splice strips

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    attach splice strips to square tubing

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    butt-up to footwell hump

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

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    measure bolt diameter

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    maintain 2 diameter edge distance on bolt thru square tubing

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    trim and cut splice for hiway peg square tube attach bracket

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    rough fit check

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    splices attached to square tubing

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    peg mounted to bracket

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

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

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    get out hole punch 3/16 size

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    punch hole in dual lock

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    like so

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

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    pads attached to bracket with fastener

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    attach to hiway bracket at footwell between protruding ribs

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

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    fits like so....

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    checking upper splice connection fastener grip length size

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    bracket in rough state

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

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    filing the edges, deburring the splices and tubes

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    adding a decorative top cap

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

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    bolt on hiway pegs

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    hiway pegs mounted

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    front view pegs stowed

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    pegs stowed offset view

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    first person view....pegs extended

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    first person view pegs in use.

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    1/4 scooter view pegs stowed

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    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
    #1
  2. climbamt

    climbamt Been here awhile

    Joined:
    Jun 11, 2012
    Oddometer:
    206
    Location:
    Baltimore, MD
    Nice job Keith!
    :clap :clap :clap
    #2
  3. damasovi

    damasovi Long timer

    Joined:
    Nov 8, 2006
    Oddometer:
    2,705
    Location:
    Ensenada, Baja California
    you keep on improving that vespa man!!

    D.
    #3
  4. hayasakiman

    hayasakiman Been here awhile

    Joined:
    May 9, 2012
    Oddometer:
    159
    Location:
    WPB, FL, USA
    Are they stainless steel hardware on aluminum?
    #4
  5. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    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.
    Keithm
    #5
  6. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    Here is a couple enhancement to the hiway peg bracket:

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    added center flush fastener, all fasteners are metric stainless steel

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

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    after 120 grit

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    after 400 grit

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    after 1,000 grit

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    brushed steel look

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    close-up of flush stainless steel fastener counter sunk head

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    attach tab holes

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    weight = 2 lbs 9.4 oz

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    as mounted after sanding + added fasteners

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    right side view

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    front view pegs down

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    close-up right peg down

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    close-up right peg stowed

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    left side peg stowed

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    offset view

    Keithm
    #6
  7. TheReaper!

    TheReaper! Been here awhile

    Joined:
    Aug 28, 2009
    Oddometer:
    653
    Location:
    S.E. Michigan
    It's a good thing we're not neighbors , we would be up half the night fabricating shit . :lol3

    TheReaper!
    #7
  8. Shirker

    Shirker Been here awhile

    Joined:
    Jun 20, 2004
    Oddometer:
    455
    Location:
    Here today
    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?
    #8
  9. gogogordy

    gogogordy Long timer

    Joined:
    Feb 25, 2009
    Oddometer:
    2,043
    Location:
    Winchester, Southern California
    I fab some of that daily, and get a good night's sleep while I'm manufacturing it.

    Product distribution begins at 0600 daily.
    #9
  10. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    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
    #10
  11. Motovista

    Motovista Parts is Parts

    Joined:
    Nov 19, 2009
    Oddometer:
    507
    Location:
    Charleston, SC
    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.
    #11
  12. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    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
    #12