Lid Compartment

The first part to be replicated was the lid of the side panel.
5 layers of carbon fiber and resin is strong enough to make that.

 

 

 

The original is 415g weight, but the replica is only 70g.

As you can see, the reverse is not really perfect. That's because is my first part.

The mould is made of plaster and plasticine.

 

Now putting the 5 layers and lots of resin between them.

Engine Assembled

Finally, the engine assembled.

Every parts were cleaned and, I must say, they were well preserved. Wear did not ocoured, which is good for a 1968 engine.
I bought this Vespa in 2002 and I trust the ancient owner when he said: "the Vespa doesn't look great, but the engine is working very well".
He was right, despite some kicks of the clutch, which I repaired with a brand new discs.

As seen, I changed the engine's support. The old one was made of aluminum and breaked when I was kicking the pedal to start the engine. I made this in pinewood, heavier but sturdy.

It was hard to put the engine working, tuning the carburetor is not easy, and there were some gasoline leaks. But in the end, I could solve the problems, with some new joints.

My right foot and ankle hurted for a few days because of the kickstarts.

From digitizing to 3D model

Digitizing is finished!
It's possible to see some bucklings!...

...and some dents on the frame.
The picture above is a 3D mesh but shaded.
Now it's time to create a 3D model based on surfaces.
Solidworks software will be used. It's not the best software to work with surfaces, but it's the one that I work everyday.

During the construction of the surfaces, there was necessity to disguise the dents and the bucklings, and put some simetry on the frame.

After long hours building ant triming surfaces, here is the result.

Looking the new surfaces over the original mesh from the digitizing, it's possible to see how crooked the frame was:
The blue it's the new surfaces and the red is the original mesh