View Full Version : Sams scooter of death

20th December 2008, 12:10 PM
Well seeing I may effectively have my own section to put my worklog in I thought why not.

I know this isnt relevent to this forum and I am not running any toyota parts but I thought people might be interested to see some custom work done on something unconventional.

I wanted a scooter that was affordable, had a clutch, air filled tyres and was relatively fast and cheap to mod and service. This ruled out any go-ped or zenoa engine. So I decided to make one that was made from the parts of a pocket bike, cheap easy and with disk brakes.

Anyway here goes:


- Heres what I started with after I stripped the frame and choped a bottom plate off


- After I chopped off the rear fork and welded on a pocket bike fork that I prepared earlier


- I braced the frame


- I welded up the rear forks properly, chopped some bike forks down for the front, bolted them to a wheel and sat it next to where I thought it would end up sitting


- My new custom fork tack welded together


my new forks welded to the original forks that had been chopped


how it made the frame sit with the lower height, notice how it slopes downwards


the front part of the frame chopped getting measured to see how much to take off


aligning the newly cut down forks and checking for straightness

20th December 2008, 12:11 PM

- Dummy fitting the engine roughly where it will be sitting bar it being a few cm higher and more towards the front of the bike


- Front part of the frame welded on and smoothed over


New headset to frame pipe welded in and smoothed over.


Vertical pipes shortened, horizontal pipe welded in, two strengthening gussets welded in.


Making some new engine mounts


Aligning the two rear pipes for engine mount brackets. The pipes have two temporary peices of steel welded to them to hold them in place which will be removed once it's welded together.


Engine + mounts tack welded to frame and also additional suport welded that has a bend in it to not hit the chain.


Front temporary bracing removed.


Forks back in and with higher handlebars fitted.

20th December 2008, 12:12 PM

- New side pipe welded in, pipe on opersite side cut and welded in, top loop
welded in, top engine mount welded, cross bar cut & welded in and I also welded all the joins that had temporary tack welds holding them together.


- Engine out with the welds cleaned up and I chopped off the temporary rear section.


- Engine reinstalled


- Cro-Mo diagonal braces welded in


- Wheel reinstalled


- As it is currently

Did some more work:


- I modified an already modified stock pipe to suit my scooter layout. I figue it will work for now till I am ready to install my fat boy pipe. Even though it's temporary I am quite happy with how it sits. When the time comes I will definetly have to install a gaurd so I don't burn myself.

I also shortened the stand so that it will work for my scooter. Originally on the pocket bike it was in a much higher postion so when i used it for my scooter it no longer worked. I took a 30mm or so long peice out of it and now it works great.

20th December 2008, 12:12 PM

- Fitted the disk brakes to the front. This was an unusally hard job to do, but now with some time and a serious amount of patience it lines up perfectly and uses all of the brake-pad surface.

20th December 2008, 12:13 PM
Today I spend a unreasonable amount of time making this:


- I know what everyone is thinking.... 'WTF is that!?'


A pictures worth a thousand words:


- This is what I came up with for a fuel tank mount, the round section is Cro-Mo pipe (same pipe as the angled brace on the rear forks) and it's quite light. When in the down position it clamps the tank quite well. I figured I would need this because it would be suject to some intense vibrations. The fuel tank is a slim-line pocket bike tank that is supplied with any fat-boy pipe, it should be enough capacity for me and look ok.

Next on my list of things is to make this mount bolt to the frame, not as easy as it sounds.

Another good day of work, unfortunetly it might be the last one in a while.


- Fuel tank mounted, tank clamped down


- Clamp in the released position


- Tank removed with clamp attached to frame.


- The clamp is attached by Cro-Mo pies that are bolted. This way the mount possitively locates and therfore is very solid and can't move. I used M5 bolts and I will source some decent cap screw high tensile ones of the right length later. My welds for the mounts ended being a bit rough for this one, but atleast it won't break.


- Showing how the mount unbolts


- I modifed my tank a little, what I did is I clamped a fuel hose on and then used a heatgun all around near the bottom of the tank. Then once it softened up I tilted the outlet on an angle at the same time as I was pulling it down. This does two things, first up originally the outlet on the inside has a decent sized lip, so the last bit of fuel never would come out, by doing what I did the lip is sunken and all the fuel will come out. Secondly the outlet is now facing where I need it and its not a strain on the tank anymore. Sure I could of lifted the tank but that would make it look less neat. Also as shown in the pic I hooked up the hoses, clamps and a filter. It's short, neat and simple, as a bonus I can still take my tank off without disconecting it.

20th December 2008, 12:14 PM

Putting the throttle on and levers in place. A big thanks to Jason from Toowoomba Pocket Racing for giving me these. I decided to keep these handlebars even if they make the scooter look a bit querky. But I do still plan on modifying the gooseneck to be about 10cm longer. I will also make up a longer bolt using a peice of all thread and a long nut.

here is what I have currently being run in in my pocketbike which will end up in this scooter:

- 2 peice head kit with 13.5:1 compression
- tiny boost port
- 33mm crank
- 50.1cc
- dellorto carby
- fiberglass reeds
- fat boy pipe
- lightened flywheel

parts I have coming or havent installed:

- tripple stage reeds
- timing key
- full circle crank
- 15:1 head kit and dome

future mods

- modifed fat boy
- central boost port enlarged and 2 more added
- ported for slightly higher revs
- balance crank
- modify the combustion chamber
- modify the crankcase for more flow
- modify the barrel for more flow
- custom dual peddle V stack reed setup?
- lightened and windowed piston

did some work during weekdays this time due to my lack of free time


- Here is the arangement I have so far come up with. I have small sprung V-brake levers for the brakes and a mini lever that I am setting aside for the throttle. I also fitted a cut off switch on the right hand side.


- I bought a length of all thread so I could make this extra long head stem bolt. To make it I welded on a car spec nut onto the end of the all thread and then ground it down to make it neat. I needed it so long to suit this...


An extra long head stem! To make this I took the original head stem, chopped the pipe off an old head stem I had, welded it onto my original


- I started and finished my deck, I really like how it turned out. I think it looks mean as is simple and light. I used counter sunk M6 screws and recessed them to be flush. I cut the plate back near the front vertical pole so that it clears the weld. I did this so that I wouldn't have to grind the weld back and potentially cause a weakness.


- Front cable put in place, attached the cable to the brakes and adjusted them. I also fitted the rear brake cable and heat-shrunk the wire from the kill switch along with it. Now that I did this it looks like one cable.


- As it stands now, I am really happy how its looking. It is still very light and easy to use. The front brakes also pull up real hard. Notice the tall headstem with some temporary primer on it. I need to borrow some scales and check this thing compared to my pocket bike, because it may be lighter. One other interesting thing is the fast I can actaully bunny hop this thing with everything attached atleast 10cm, now that is unusual for any scooter. I am hoping that because of the light rear-ward weight I might be able to do some nice wheelstands with some carefull weight trasfer and some power.

Next up: Custom throttle link and cables + rear brakes + custom tensioners

after that its ready to ride!!! I can't wait.

20th December 2008, 12:15 PM
well it finally runs!


Here is how I did my custom throttle cable, I just clamped two cable together, great to work on and does the job flawlessly. I also made it do the cable has a section further up the frame for decreased friction.


A closer look,the clamp is off a brake caliper that has been customised and some washers added for clamping.


The rear brake cable; this also has a bare section for decreased resistance, it was at first much harder to use that the front but with this and some PTFE lined cables its pretty good now.



I will do another update to explain what has since happened. But I will say right now I think in due time I will be able to do some killer monos and it's a blast to ride.

I initually ran the engine with no spark plug cover and not suprisingly I copped a few shocks. Other than that it ran great and felt good. I fitted a rubber boot over the spark plug and also went to fit my other engine.

What happened is that I was ready to change the engine and I did. Interestingly enough the chain was adjustable perfectly for the previous engine but when I swapped to my decent engine it wouln't fit. It seems that theres a bit of a difference between castings and the heights of the mounts. I tried running a chain a link longer but it was too long. I bolted it up still and used it. I rode it and it had twice the power and that was with the standard pipe, it was great.

I initually filed the engine mounts down a bit to level it a bit like I did with the other engine, but to correct the chain length issue I filed it down some more and retried it. It didnt make much of a difference so I took it back off and then got the grinder out and took more off. I retried and it seemed like I took too much off. I tried two different sizes of washers and I when tried the thinner one it suited perfect.

However when i tried to start it it was dead. I spent half a day trying everything and I found nothing. Finally I put my orginal engine back in and it fired up. I figure I just popped a seal somewhere or something I will find out soon.

20th December 2008, 12:16 PM
my scooter as it was:


I adapted the fat boy power pipe, but purposefully made it 10mm too short to tune it.


The section of the pipe I never liked, I thought this would be bad for it so I wanted to replace it.


So I started to make up a new expansion section.


Lining it up.


One end welded in and marking out where to cut.


The nasty step in the old pipe that I thought wasn't helping.


All welded up.


Bolted on and painted.


How it is now.

20th December 2008, 12:17 PM
looks like I am going to sell off all my old cag engine parts and not use them ever again, because I have this.....


a F1 Balata rep 40cc engine thats rated at 7hp standard. I also got a rep 19mm Dell'orto carb (original 14mm), different pipe and 2 x tripple stage reeds. It should tottaly haul arse

the engine mount was no good to me in that position so I wanted to see if I could reverse it so it faced down. I took the head off and while I was at it I took the bore off to see how it was made and why it made so much power.

Heres with the head off and the piston at BDC:


the ports are absolutley huge in this thing, the exhaust ports take up like 1/3 of the whole diameter and there are 4 transfer ports and 1 boost port.

Heres another pic of the bore with the barrel removed:


and of the V stack reed system, its very large, very close ot the piston and most suprisingly it has had some aditional hand porting beween the intake and the transfer ports. I have never seen such quality in a 2 stroke and it came out of China which is downright scary.


and yes I did manage to reverse the head. I have designed most of the new frame and I will have to do some major chopping to make it fit. I hope to do it this weekend.

20th December 2008, 12:18 PM
I managed to do a real good days work, which I was quite happy with seeing that day was meant of been 38 degrees.

Heres what I started with, engine out, top support bracket bent up:



With the top part chopped off, it wasnt easy doing this when it was so hard to line up and worked so well.

I made up a U shape out of cro-mo steel and I wanted to max out my clearences. So I decided to keep grinding it down till it only just cleared the wheel, heres how it looked when it was the right height and dead level:



New section tack welded in and looking good


Engine roughly in place without thrid bearing sprocket support, notice the curved rear pipe that I used to clear the wheel and have the side supports lower.


ends of the bars shortened and chopped vertical, new U suport welded in for the front engine mount (also Cro-Mo steel), chain in place for basic alinment checks and also some of the pipe ground down on both sides to lower the engine even further.


Front engine mounts in but not welded so I can get the alingment right. I later used some spacers at the front to get the heights right.


Front section welded on properly (so to speak),front mounts tack welded on and one of the two rear engine mounts welded in.

Thats all I have done right now and I will need to grind more of the pipe away to clear the engine and then weld a plate in to cover the hole. The other rear mount needs to be made but that should be real easy now the alinment is all good (I think!!!)

it looks like I will be temporarily be using the pipe in the stock position and mount the fuel tank off the side, I do plan on modifying it the same as my last pipe but I want it to just run first and then maybe experiment with pipe mods before reshaping it into an elaborate shape to suit the frame.

I also plan to make my own stainless steel fuel tank, should look and work great.

20th December 2008, 12:19 PM
another update: I finished my engine mounts, they are fully welded in and the engine is bolted up. Heres the rear mount:


I also finished the frame recess. To do this I put a piece of flat steel on top of my cut out, tapped it with a mallet, tack welded it, ground it one side, tacked it again, ground the rest, welded it all and then did the finishing grinding. A little bit of stuffing around but I love the result, I think it looks great. here it is:


and with the engine in place:


oooh also I have a really nice suprise....


its the real deal: a NOS nitrous kit, I will convert it to a wet system though.

20th December 2008, 12:20 PM
well this thing is finally running.

The first time I got it going I went about 10 meters before I snapped a chain link.

I wheeled it back home and modified a BMX chain-splitter to split a link instead.

Back on the road I go up the hill near me and I accelerate a little and it just lifts the front wheel straight up and throws me off. Worried that I might damage the threads holding the exhaust I wheel it home again and weld a brace on the power pipe. Welding was difficult with my hands shaking so bad.

Back on the road once again I am really carefull and I find it will lift the wheel up a hill or down a hill, truly scary. While I am riding up a gavel path up a hill I accidently give it just a tiny bit too much power and it lifts up the front wheel and because it was an offcamber track it of course just steered off the track and down an embankment. After using my increadabile butt saving technique I stop myself getting too many induries and then go home.

At home once more my hands are shaking badly and I am left thinking "I have made a monster..."

Oh i love it

I will post a pic shortly and I have also managed to get this thing in action on film which I plan to upload soon to an online host, hehehehe

I went for another spin, even at 60km/h the thing feels like its leaning back from the power, I think it may go up to 80, I need to get a speedo for this thing.

Also it broke down, it was spluttering at idle and I stopped for a moment when it just died on me. I don't know why.

well anyway heres a current pic:


the time has come....

youtube video (http://www.youtube.com/watch?v=5eA0_Zsd0G0)

20th December 2008, 12:21 PM
Well quite a bit has happened,

- I had a faulty ignition coil which I changed

- Been doing heaps of reading and finding out what I should be doing. BY my basic measurements right now my intake ports are tuned to 6500RPM and 7000 for my exhaust. I will look to change this to 11,000RPM.

- I went for a spin and with my friend following me in his car found that my top speed is 70km/h, however it was the same up a hill so its purely rev limited. I measured the wheel and worked out I was doing 12,300RPM. With the mods I plan to do I hope to get it to 14000.

- I found that my engine has some massive flow restrictions in regard to the reed valves and the engine would of been tottaly straved of air at any decent revs, I will modify the housing to fix this.

- I did some porting of the chamber by opening some up, reshaping, smoothing and also deshrouding certain areas.

- I started working out the dimentions to 3 possible expansion chamber setups and started making the simplest first.

- I have chopped the frame in two and extended it whist at the same time starting a rebuild of the rear section.

Enough talk heres some pics:

Frame stripped down and ready for work

Chopped in half!

Extended with some Cro-Mo tubing, notice the slots cut into the front sections for me to weld through.

new pipes welded in place

An expansion pipe I am working on

20th December 2008, 12:23 PM
ok rear part of frame chopped off and two new cro-mo bars welded back in using original diagonal braces:



Simpler, neater, lighter and stronger (I think)

What I need to do now is make another deck plate, a new front engine mount, add a few gussets etc..

This time round I will make the engine mount brackets very short and slim, I will use Cro-mo just like the rest but this time they will be out of the way. last time it was tricky to work on my exhuast and I didnt like it one bit.

Also the whole frame is significantly more rigid now and I am fully confident in doing jumps now which is good.

The only bad thing to report is this frame is using up all my Cro-Mo supplies at an alarming rate, and at about $20 to 30 a meter and a one and a half hour drive one way during buisness hours to get more is not a good thing..

update Dec 17

I was doing some porting to my barrel, heres a before/after:


- I ground the side trasfers to have less of a step, filled the remaining step with a high temp epoxy and then sanded it
- Opened the boost port entrance, smoothed it and took a nasty step out of the exit
- smoothed the trasfers and took some uneveness out.
- ground down the part of the barrel that protruded into the intake and also angled what was left
- widened the exhuast port

I will find out the results shortly when I run it next.

made a new power pipe also (top one):


I have already welded the stinger on (tail pipe) it too. It is meant for more top end that the first.

another pic I forgot to post:


there was a step in the exhaust port which I die ground out, then widened the exhaust port window itself and then I finally smoother it all with a barel shaped flapper wheel. Looks better in real life than the photo. Notice also how the barrel now curves right into the transfer ports.

This is how I ended up re-doing the front engine mount:


Once again all cro-mo steel and its slim, simple, light and tough. Worked out better than I expected, I do hope its strong enough but I am very confident. Another thing of note is I went out of my way to make it as far away as practically possible from the flange. This is because I previously had issues trying to do/undo the bolts holding the exhuast flange in place, so this time I made it so I had decent access, seems to of worked too.

Different view:


and with the old deck plate temproarily in place just to make it useable till I make a new deck of a simular design:


20th December 2008, 12:24 PM
small but disapointing update:

A couple of weeks back I modified the rear fork on my scooter and also fitted a new chain and air filter onto my scooter afterwhich I took it for a ride. I got from the top to the bottom of the short hill and the brand new chain snapped and broke my third bearing support for the sprocket and also tore a tooth off my drive gear. Predictably I was pissed seeing it wasnt a no-name brand (Fenner). A week later I found my air filter had slip out from under its clamp and had since ripped..shit. Anywya I have since sourced some replacement bits and hope to be back on the road soon.



finally an update!

I have changed the damaged parts, fitted my new Japanese heavy duty chain and made a tensioner as shown below:


Also I measured the plates of the chain links and the old chain had 0.6mm thick plates whereas the new chain has 0.9mm thick plates, also the pins are over 2mm longer. So I think its safe to say that at a minimum the chain is 50% stronger before the higher quality is even counted.

I was getting hyped up about taking it for a spin when it wouldn't start, With some aerostart it kicked over but only ran with it being sprayed in. I checked the carb and found it wasnt giving any fuel so I took it apart, found the fuel inlet valve stuck from the oil out of the evaporated fuel, freed it up, put it back together and it ran first pull. I went to take off though and it just died, as soon as I was off the thottle it started again. I just got pissed off and gave up for the day. Next step is to take the carby into peices, clean it out and put it back together.

I should also put some temporary paint on my frame untill I sand-blast it, damn that Cro-Mo rusts fast.

In other smaller news I am working out a plan to make a kick arse Lithium Ion powered LED array for some night time riding.

20th December 2008, 12:25 PM
dude you are a freak......

20th December 2008, 12:52 PM
fucking hell. that thing is insane.

20th December 2008, 12:56 PM
holy carp that is awesome!!!!

20th December 2008, 01:44 PM
scarey, if u bring that to the meet, please keep within 50 metres away from me so atleast i have time to climb up a tree

20th December 2008, 02:33 PM
hhehehee, I will bring it to a meet in the future once I have made it a little more rideable

well I hope I have now justifed the two wheeled section of the forum now

20th December 2008, 02:37 PM
oh I forgot to mention I have an update, this thing is running right now but the carb is giving me the shits big time. I mean this thing was a handfull before but right now the carb causes the engine to bog down bad till about 10km/h and then take off badly, as if I didnt have enough to scare me.

I have a Go-cart tacho and I gave it a quick rev for about 3 seconds and it went up to 15,000 RPM and it would of gone higher had I had the balls to hold the throttle on longer.

I also had a friend follow me in his car a while back and I found my top speed was limited by my revs and I sat on about 70km/h, I plan on changing my gear ratio again soon though.

20th December 2008, 02:59 PM
Dude first of all HOLY SHIT! Should put Suicide Scooter graphics on it.

Awesome build I love seeing build threads for motors onto scooters and bikes,People put so much damn detail and quality into them it makes me think imgaine the cars they build!

16" Scooters FTW I had one I put 20" mounatin bike suspension forks onto and mounted a rear disk brake I ended up riding it down some crazy hills and ripped the forks off the frame landing a big downhill rise and did a fully hecktic nutbag to head stem crunch then knocked myself unconsious,possibly the ball pain put me unconcious.All in all fuckin fun and practical and yours looks spastic at half throttle.

Good luck with it.


20th December 2008, 03:00 PM
that scooter is sweet sam alot of time and effort put in

20th December 2008, 04:51 PM
sam we should go for a ride lol,

ive been riding for around 8 years.

heres some piccies of my scooters

Blue one = 27.5cc around 55-60km/hr

Orange one 32.5cc around 55-65km/hr

Grey one 62cc trevor simpson limited edition, gearing atm gets it to around 85-90km/h

They all come out 22.5cc except the grey one, so imagine the work thats gone into them. Plus first two a direct drive (spindle driven)


20th December 2008, 06:29 PM
Jdm-Mcc: "suicide scooter" I really like the sound of that, infact I will change the name of thread!

AE86R: sounds good, whats your location?

21st December 2008, 02:02 AM
looks like fun...

...its ALIVE!.... ALIVE!:


21st December 2008, 12:03 PM
nice work sam! looks like a scary amount of fun!

21st December 2008, 12:17 PM
man what an effort.

just read the thread! kudos to you!

i'd be shitting myself going 70kms on a small as scooter hahah!

21st December 2008, 02:27 PM

21st December 2008, 05:54 PM
also keen to see some videos!! :thumbup:

21st December 2008, 09:09 PM
Fuck, someone has to much time and alot of skill to spare :) and alot of film haha

21st December 2008, 09:13 PM
this is truly a death machine !!! u nut !! lol i like it alot, any kiddo that see's this is gonna want one for xmas xD

22nd December 2008, 07:08 AM
best build thread ever!! haha

22nd December 2008, 07:41 AM
thanks for all the positive comments guys,

this is the only vid I have, yes there will be a helmet next time


22nd December 2008, 08:30 AM
thanks for all the positive comments guys,

this is the only vid I have, yes there will be a helmet next time


holy flap jacks! thats unreal. what a nutter. can hear him coming from a mile away! hehe!

nice vid :yeah:

The Kid
23rd December 2008, 10:04 AM
Incredible man, what a beast. I love the ideas and fixes you've come up with for this thing, so simple yet so effective.

23rd December 2008, 10:55 PM
lol this things insane!!

i want a go!!!!

23rd December 2008, 10:59 PM
sadly this thing wont be pulled out and finished untill my house gets done, after that though I will be getting my nitrous bottle filled up!

24th December 2008, 12:07 AM
arnold2489 (3 weeks ago)
that would be funny if he skid out and got hit by a car and his scooter got stollen by a negro


crazy stuff man

24th December 2008, 12:09 AM
yeah I laughed when I saw that someone posted that my youtube video

24th December 2008, 12:33 AM
Very nice work! This fucking awesome!

I want one!

24th December 2008, 12:47 AM
I am suprised on how much of a possitive reaction this worklog has recieved in this forum, oh well once again thanks for the praise guys. This will be back and I will post it on here when it does happen

24th December 2008, 12:52 AM
Skid vids!

26th December 2008, 11:26 AM
What a work of art Sam! ive got a complete 110cc pit bike i was thinking of doing the same- expect backflips!!!!!!

26th December 2008, 11:08 PM
110cc would be ... interesting

2nd January 2009, 06:08 PM
u mean a 110cc would be CRAZY! Its got a bent frame so its going to waste. its a 4 speed too so wheelie bar is a definate... man ur a bad influence!

2nd January 2009, 06:27 PM
yes I am, and you better have wheelie bars as long as your frame, also have a fairly laid back headstem angle, its like the castor for a car.

2nd January 2009, 06:37 PM
another reason i want to have your babies sam...........................

2nd January 2009, 06:53 PM
I am going to pretend I didnt hear that! :)

2nd January 2009, 09:08 PM
yewww this thing is mad!!!

i want one!

how many kw at the wheels ahahahaha

good work, get that nos on ahaha

3rd January 2009, 12:28 PM
prob more KWATW than most 4k-c's make

hhmm, should do a 0-60 or 80 race.. scooter VS stock ke70 hahaha!

3rd January 2009, 12:35 PM
ill go it, just bring it up to coffs harbour

worked 4k vs crazy death scooter

1st September 2009, 02:03 AM
tiny update; my scooter is now on my website


1st September 2009, 09:02 AM
had a look at your site sam, pretty impressive

1st September 2009, 09:54 AM
thanks, I am working on it. I could use some input here:


now for an update on my scooter:

my engine is still in peices however all the machining I was doing is done, I have picked up new bearings and when I get a moment I will do some final checks and cleanging before it comes back together.

1st September 2009, 04:33 PM
that thing is nuts!!!!

you should sell them! I would buy one lol

1st September 2009, 05:32 PM
if I made these I would need a disclaimer that requires atleast 2 witnesses in the room. The interesting part is the mods I did are meant to increase the power to 15hp, sounds like BS to me but either way it should be fun

1st September 2009, 09:14 PM
Fucking love it! (caps)

6th January 2011, 09:05 AM
just seen this thread now - top work sam - any updates??

6th January 2011, 09:26 AM
well this is digging up an old thread.

Yes I do finally have updates I have started to put my rebuilt engine back together, one of my bearings a little but too tight so I have to heat up the housing and try again. I want to have it going on the bench in the next few weeks.

8th January 2011, 06:34 PM
sweet i thought this was dead! add nos

14th July 2011, 08:36 PM
i gotta get one of these!!!!

14th July 2011, 08:52 PM
Im interested in the death part.