PUCH 250 SGS

Restoring a barn-fresh 1966 Sears Allstate

Spring in my step

With spring just around the corner, and the annual pilgrimage to the CVMG Paris Rally, I have been working on getting my Puch 250 SGS suspension overhauled. The rubber  seals have long gone brittle and what little oil remains is thick and gooey.

IMG_0003The 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 seek out a hydraulic shop to see if they can straighten them out.

I took the shocks and forks apart to assess the condition of the components in case more than consumables are needed. Luckily,  seems all is in order, just dirty, gooey and decomposing or brittle rubber bits. One fork seal was brittle enough to almost cut my hand, the other was fairly supple.

20150218_093335_cThe rear brake lever (part no. 175.4011.2) I ordered from Motor West arrived today, or should I say the envelope arrived. It appears the envelope tore open and the lever fell out.

Packing tape was invented for a reason, Matt. *Update: Matt has graciously offered to send me another at no charge. That’s class.

posted by Fastback in parts,Puch,Puch 250 SGS,restoration and have No Comments

New tires – old Puch

Original Semperit tire.

Original Semperit tire.

The original equipment Semperit tires on the ’66 Puch 250 SGS are getting a wee bit, well, tired. With my current push to get the old girl road legal I’ve ordered tires and checked the brake pads. Really, it’s time I showed the bike some love, especially after several years of being ridden hard and put away wet at Paris, literally.

I’ve ordered a pair of Duro HF319 from a local dealer, the tread pattern looks pretty vintage so they should look right.

DURO_HF-319

Part number : 113113

  • Designed as a general replacement tire
  • Excellent load carrying capabilities
  • Can be used as a front and rear tire
  • Excellent puncture resistance

I mean really, isn’t that the basic description of a tire?!

I will also look into getting a 16″ rim for the Velorex to lower the hack as it is currently wearing a 19″ – then perhaps I’ll need another Duro.

Sears Allstate Puch 175 60_57

click to enlarge

 

I came upon this page from a Sears catalogue a while back, it is a great illustration of the Puch badged as a Sears Allstate, although I think the illustrator didn’t understand how brake and clutch levers worked. I’m pretty intrigued by the brown sack outfit the guy on the left is wearing. Is that rain gear? 

 

 

 

 

posted by Fastback in mechanical,parts,Puch,restoration and have No Comments

Paris CVMG Rally – 2014

This year we decided to bring a plethora of bikes in a cubevan. We thought we were being smart and prepared but of course wrangling children, bikes and getting out of town on a Friday afternoon was a bit challenging.

We managed to stuff into a cube van the following:

  • 3 x Norton Commando
  • 1 x Honda Ascot
  • 1 x Puch with sidecar

As other years it was a scramble to Paris and we arrived at the registration desk with 5 min to spare (7:55pm).

Here are a few photos to give a taste of the weekend.

posted by Fastback in cool bikes,events/shows,Norton Commando,Sidecar and have Comments (3)

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)

Puch parts – and progress

I bit the bullet and ordered a new (low) Magura handle bar, and a complete headlight assembly as my chrome rim is shot and the reflector is completely fried (see photos). Ed (from the forum) and I grouped up on an RBO order to save on shipping.The headlight is euro spec, with a different build and a separate pilot bulb. Luckily I found I have a euro spec bulb, I think it was thrown-in at a swap meet purchase. I love the Puch logo on the lens.

I took the opportunity to dig into cleaning up the handle bar clamp as it is not available from RBO (I didn’t bother to check other vendors). The clamp was so corroded it was like a flaky bar, I took off a lot of material to get it down to where it was reasonable to try and polish, it came up rather ok, the before photo doesn’t show the actual corrosion eating into the alloy. The levers polished up nicely too, the lever and the clamp seem to be different alloys as they patina differently. I’m not going too crazy polishing, just getting them back to shiny so it looks good with those sparkly new bars.
Its nice to actually do some work on the Puch 250, it has been a long time sitting in the garage, waiting patiently.

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