PUCH 250 SGS

Restoring a barn-fresh 1966 Sears Allstate

bondo, primer, fender, nacelle

IMG_0003_nacelle

filled and primed

At long last I am actually doing some real work on my ’68 Puch 250 SGS. I replaced the oil in the tank with some TC-W3, and I think I’ve burnt off¬† all the old 10-w30 that was lingering in the system, much less smoky now.

I’ve fitted the choke plate and it works great, the bike is a 2-3 kick start; replaced the lower bolt on the chain guard (flowed the brazing to remove the old bold, re-brazed a new one on; filled holes and primed the nacelle; repaired a crack in the fender, banged out a few of the dents, and slathered on a liberal coat of Bondo.

IMG_0103

removed a rusted/crumpled section out of the headlight edge.

I initially experimented with trying to stick weld the sheet metal, I know it can be done, but it is out of my skill range and I don’t have the time to practice. I did fill one hole on the nacelle¬† but opted to brass braze the others as it is faster and well within my skill range.

It is hard to articulate just how badly dented the front fender is, it resembles a sheet of paper that has been crumpled and smoothed out again, the shape is there more or less, just very lumpy. This can be seen in the picture where I ground off the paint before the resin filler. I’m using a quick-set filler, must say I love it, really speeds up the fill/ sand cycles.

IMG_0033_fender_bondo

first round of triage

The fender will make a thud sound when finished rather then the nice ringing ding of an all steel fender. I suppose I could buy a less abused fender off ebay, but that wouldn’t be quite right.

IMG_0030_fender_braze

Brazing the crack.

posted by Fastback in mechanical,restoration and have Comments (2)

2 Responses to “bondo, primer, fender, nacelle”

  1. Leigh says:

    I hear you on the crumpled-look, mine is much the same. ditto on how getting a replacement just doesn’t seem right! love the blog, very helpful in keeping my motivation up through my restoration (’66 250)

  2. […] forks I discovered are bent, not surprising considering the condition of the front fender, the dented fork covers and handlebar into the tank. One is bent more than the other – I will […]

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