PARTS

When riding or restoring mobylettes you sometimes .....need parts.
There are many companies, that reproduce parts and still have NOS-parts. Whenever they cannot supply those parts; it is getting time to start your own manufacturing.
In the past we made fuel taps, but as those taps took too much time, we finally stopped manufacturing them.


Below our main groups with some examples of parts.
    Ignition
    Saddles
    Frame
    Emblems
    3D printed parts
    Special bolts and nuts
    Gaskets
    Various articles
Jumble Heerhugowaard NL


    I G N I T I O N    S Y S T E M

EBS-2021 IGNITION SYSTEM

In fact this system is an improved version of the Motobécane system from 1968.
No electronics, but a simple straightforward technology, that can be fixed when you are in the middle of nowhere.
There are several versions, because of breakerpoints, ignition groundplate and mounting position of the external coil.
Some people want to hide everything behind shields, while others place everything full in sight.

Are those sets still available?
Sometimes we have some sets available in our stock. It is however difficult to find certain ignition parts, that meet our high standards.
One of the disadvantages of Corona was that a lot of jumbles have stopped.

FEEDING COILS

One of the best ideas of Pantin was rewinding old high tension coils as a feeding coil.
Thanks to this idea lots of feeding coils were suddenly available for engines equipped with an internal coil.
There are several advantages when applying this system:

  • There are no fitting problems, we keep on using the old steel core on the same place.
  • All the high tension part have removed from the hot spot under the flywheel
  • Electronic components don't like heat and an excellent ignition system can give problems during a long trip in the hills.
  • This system is quite simple and can be easily repaired when you are riding in the middle of nowhere.



  • Picture on the right: an example of a M1-feeding coil.





    More coils
    This system can be applied on other cyclemotor brands, too.
    Whenever they have applied a flywheel-ignition system with breaker points, then you could rebuild your ignition system.
    People are always surprised about the results. Very often the engine is more powerful, because there are no missing strokes anymore.


    Cady feeding coil

    TERMINAL

    The best ideas are afterwards quite simple.
    The simple ignition terminal, which is mounted on the spot of the former internal capacitor, is such an example. This little screw connects up and till three wires and makes an end to the complicated mounting of several wires at the breaker points.












    As time goes by, we need more and more different terminal versions. A very rare version of the early stator-ignition plate had a grease pad for the ignition cam.
    This pad is locked on a tiny shaft and besides it is locked against rotation by the wall of the capacitor.
    As we normally remove the capacitor right next to the external coil; this new terminal had to be provided with an extra function.
    terminal examples

    INTERMEDIATE CABLE

    In order to connect terminal and high tension coil a cable is needed.
    Some people use a piece of wire and some kit. Mostly this works well for some time, but a more professional cable will last longer and is easier to mount.
    A special plug makes mounting easier and a hard profiled hose will prevent insulation problems.

    intermediate cable

    EXTERNAL CONDENSATOR

    Condensators for mopeds and motor cycles can be bought everywhere and yet we assemble our own type!

    Why?

    The quality of many standard capacitor is poor.
    After troubles in Luxembourg on a warm day in 2006 we decided: 'From now on .... we will only use an external condensator'. Mounted on a cool spot it will give less troubles. Problem is of course the vulnerability on a motor cycle or moped.

    Evolution

    Funny to see how this casing has changed in time. The first ones (not shown) were quite ugly.
    We kept on improving them. In fact this tubular condensator offers the highest quality, but making them is very time-consuming.
    That is why a new approach saw the daylight.
    A new rectangular design and instead of 1600 Volts it will operate until 600 Volts for alternating current. Recently we provided its wire with a cable supportpiece made of black POM as shown in the bottom right corner.

















    Special version

    (not displayed) On request a special 2000V DC-version was made, but it became much bigger than the standaard one. Nevertheless it will fitt perfectly on a standard external coil.
    However we advice the small rectangular one, because its is much cheaper and during tests this small condensator seamed to be very reliable.







        S A D D L E S

    BUDDY SEAT EXTENTION

    Some years ago we started with big saddles, because we knew that you certainly will face bottom problems when riding long distances.
    People making long bicycle trips: often are getting injuries.

    We also suggested to use a big piece of foam when removing a nice buddy seat is out of the question.
    At that time two friends tested a simple piece of foam, which had been wrapped with ductile tape.
    It worked fairly well, but within an hour all air had gone out of the foam.
    A hard flat seat cushion was the result; by turning the cushion regularly its comfort improved significantly.

    So we changed the design, using NASA memory (lazy) foam and a dual layer of high elastic silicon rubber.
    Result: it feels much better with no pressure points.
    We tested this special pillow during long rides in France last year. A cotton cover is used for good ventilation.
    Our conclusion is: great extention to prevent pressure points. It makes ride of more than 10 hours possible.
    The cover has now been equiped with a Velcro fastener for easy removal of the foam and cleaning of the cover.



    cover4BB

    SADDLE FOR VERY LONG TRIPS

    When you are planning to make a long trip on a mobylette provided with a buddy seat, you should take some precautions to prevent red and blue stripes on your bottom!

    We tested buddy seats from other marques, but all buddy seats were not acceptable.
    A simple and quick solution advice is: use a large piece of foam rubber!
    But - as always - there is a better alternative: a motor cycle saddle such as applied on old English motor cycles.

    We bought some for our long trips in 2017. Of course this saddle doesn't fit on a mobylette and some additional parts had to be designed to get the saddle in an optimal position.






    The second image on the right shows a special stainless steel support, which embraces the saddle pipe and is connected with the saddle frame by a hinged bolt.

















    A lot of experimenting was done with the 2" and 3" conical rear springs, but the problem was not the suspension itself.
    Main question within this project was:" how can we lower or prevent high pressure points?" Eventually we have chosen for short 2" springs instead of 3" springs and some additional layers of hard rubber and foam rubber under the saddle cover. A luggage carrier, some steel plates and two springs will support the saddle from behind.

    Finally when all functioned well, we found lot of space under the saddle; we gratefully accepted this for a small saddle bag.










        F R A M E   P A R T S

    A good example of a "nowhere-to-get-part" the front fork leg of an AV31.
    Perhaps you find a pair, but at the underside, grease and sand mostly have affected the diameter of the shafts.
    This will result in too much play in the front suspension.
    Fortunately we have new forks from the seventies, that we can dissasemble and use a piece of their shafts.

    LUGGAGE CARRIER FOR AV92L

    Last year our man Stan needed a luggage carrier on his new AV92L for his long tip to Spain.

    Those racks are hard to get and often quite rusty, so he decided to design and manufacture one.
    He chose - very wisely - for stainless steel pipe and MIG welding.

    On this AV92L you will see a small Lycett saddle for lightweight motor cycles. A nice alternative for mobylette riders, who are fond of long distance runs.

    Actually saddle and carrier were just a small part of this project. We saw this AV92L several times appear on the Dutch auction site Markplaats.nl
    Several owners decided not to finish this project. A lot of restoring had already been done, but it seamed that there was a big problem.

    Later we discovered a frame number under a thick layer of paint and the relay box definitely needed a total overhaul.

    carrier

    LICENSE PLATE HOLDER

    At the time that in the Netherlands ugly license plates were introduced, we were restoring some firm mopeds. On these SP98 and SP94TT a firm licence plate would not conflict with the model, moreover a Lucas tail light could be added with a brake light and a license plate lighting. A special mould was constructed for pressing the plates. The design was inspired by Motobécanes licence plates on the vélomoteurs. We still have a few of these plates in stock and of course the special mould.










    This heavy piece of metal is not shown under "tools", because - being a part production tool - its application is better seen here.

    Press for license plate holder



        E M B L E M S

    FRAME EMBLEMS

    Several years ago a number of emblems was manufactured by way of laser cutting. Stainless steel was one of the options, but nowadays aluminium is possible, too.
    Today you can buy these emblems anywhere for a fair price.










    Other emblems must be handmade: this means sometimes a lot of work.
    Take a piece of aluminum, a drill and file and start working..... However from time to time new initiatives show up.










    Recently Jozef Vaessen machined next emblem. Not completely done, but very promising.





    Mobylette emblem by J. Vaessen

    TANK EMBLEMS

    Tank emblems are pressed in heated plastic. This can be done because we have found several original compression moulds. After compression there is still a lot to do: sawing, grinding and painting in the desired colour. Actually, this is done for good friends only and for our private projects, because making these emblems is time consuming.

    The small screws threaded with M3 x 0,9 must be manufactured, too.

    The black and gold version was special made for some SP98's.

    In summer 2017 we received a message that MBK gave a French company VSX permission to reproduce spares. From now on this company offers you new emblems 'Mobylette' and 'Motobecane'.
    Mobymatic is not on their program as far as we can see.
    VSX-France



        3D - P R I N T I N G

    3D PLASTIC & METAL PRINTING

    A technology, that already exists for many years, but is getting grown-up now.
    Our designs will be sent on-line to a professional manufacturer. They will start checking if the object is well designed to prevent problems during manufacturing.
    The yellow plate used to be compulsory in The Netherlands in order to recognise a moped in traffic.
    With 3D design and printing you can easily personalise such a plate.
    We already designed many plates in PA12 (nylon), but printing on a flatbed printer is far from cheap.
    Quality however is excellent, and that is the only thing that counts for us.


    SP98 housing for H14 Gurtner-carburettor

    A recent PantinNL-design is an air intake cover for mobylette models SP98 and AV98. Up till now it has not been printed yet. To order just the outer casing is pretty expensive. But when somebody is desperately looking for this part and money plays a minor role, then it may be a nice solution. Perhaps I order one on Black Friday. I do not need it right now.



    Variator cage by Frank Franssen from the Netherlands

    An other thrilling design is from Frank Franssen, who is experimenting a lot with Malossi and MBK variators. For his new variator he needed a special cage for 6 rolls. The material is PA12 (nylon) and is quite strong.



    3D-home printing

    You won't find a simple extrusion 3D-printer here. We prefer a 3D flatbed printer, because distinct gradients in temperature as noticed at extrusion printers, can lead to cracks in the part.

    The advantages of 3D outsourcing are clear:
  • No high investment.
  • Better quality.
  • Many different materials.
  • No production troubles.
  • It saves room in your workshop.
  • No smells.

  • RELAY BOX CAP

    This cap can be used for a simple relay box on models like: AV92, SP93, SP94TT and 99 models. Looking at old caps, mostly their colour has changed from white to yellow-brown. We have chosen for nylon and several different designs have been made.
    Its definitive shape is a matter of time. Price is interesting (under 7 Euro!)

    cap relay box

    TANK SCREW CAP FOR AV42/44.

    This screw cap can be found on the AV42 and AV44 models from 1968 and later. Before 1968 the push-pull tap had a much smaller cap.

    Suddenly we were running out of stock, naturally when we needed those very badly.
    Happily a good friend could help us, but it was clear this cap will be hard to get next years.
    A digital version was already available, so we only had to fine tune the rectangular hole, that offers a special locking function.

    screw cap AV42/44 tap cap for tap wirh a long spindle (AV42)

    TANK CAP FOR KAPTEIN MOPED EARLY FIFTIES.

    This project is just but a study to examine the possibilities for 3d-printed spares that contact E10 (petrol containing 10% alcohol. Finally we intend to print some in PETG plastic, whereas the stainless steel-bronze version is mainly meant to discover the limits of modern printers.

    We were especially interested in the way how all fine details of the logo would be represented.
    Stainless steel printing requires however wall sizes of 1 mm at least. After several examinations it was clear that the design had to be changed thoroughly.
    For its sealing function we have applied quad rings. On the right a prototype in red nylon is shown.





    Stainless steel version!

    Dimensions and details of our red proto were conform expectation. Both quad rings fitted perfectly. After some checks and a little fine-tuning, our stainless steel version was ordered.
    At Pantin we still had to remove some powder rests which had not been removed by the factory. On a lathe we had to machine the grooves for the quad seals.
    With the right stitch chisel (tungsten carbide) and some lathe accessories this was a piece of cake.
    The first 3D-printed - fully functional- fuel cap was a fact. This summer it will be tested during some rides.





    Vent hole

    In order to avoid under-pressure in the petrol tank: a cap is mostly provided with a vent hole. Small holes and often filled with powder. Normally you have to drill that hole again. In case of stainless steel you must be very careful, because a broken drill is hard to remove.
    In this design we have used the idea of a later model, where a small pipe with a tiny bore leads to the vent opening.








    Advantage of a flatbed printer

    On the third picture of the metal version, you see Pantin printed in a up-side down position. Thanks to the technology of a flatbed printer this is possible.
    A common extrusion printer has to work with all kind of extra supporting material. Supporting material means a bad influence on quality of letters and small emblem details; besides it means extra work to remove all supporting material.
    In fact you should always adapt your design for the way the object will be manufactured. When using a extrusion printer you simply skip text on that - impossible - spot. As the demands of wall thickness are less rigid for most plastics, you can make the letters more accurate and smaller.



    More studies: aluminium and POM

    Unlike the previously printed objects we also had a different approach of manufacturing.
    Jozef, who is a specialist in programming NC-tools made some caps in aluminium and POM. On the right an aluminium version is shown, which was turned on a lathe and milled afterwards.
    Those caps look very nice; however better results will come when our design will be fine-tuned for his machining-tools.
    Nevertheless this cap is ready for use and will certainly function well.









    OTHER EXAMPLE OF 3D METAL PRINTING

    A brand new promissing technogy for our hobby.
    Conform the plastic printers, a computer design in .STL-format is directly send to the manufacturer. They will check if the object - in that kind of material- is well designed for manufacturing in a 3D printer.

    The ring has made of 60% stainless steel type 420 and 40% of bronze.

    After receipt of this ring we checked all sizes. The inner hole size=28mm was 0,2m smaller than the nominal size in the drawing, but beforehand we had already a tolerance of 0,5 mm in mind.
    Some machining will achieve the perfect tolerance. It's for us a nice learning process for 'How to construct a part for 3D-printing?' Next designs are already planned.



        B O L T S  &   N U T S  


    SPECIAL BOLTS

    Special screw thread... a problem for many, because normal bolts and nuts don't fit.
    Not for us anymore: making those and applying a proper heat treatment is no problem. Sometimes bolts have to be hardened and tempered for demanding functions.
    Rivets is an other category; when we need a special size we just make those using a lathe and applying a proper heat treatment afterwards.



    Special bolts


         G A S K E T S   &   S E A L S  

    GASKETS

    Not long ago paper gaskets could be a temporary problem. Nowadays most joints can be quickly manufactured out of a piece of packing paper. On the right item #1 the often forgotten paper packing which is located behind the ignition ground plate.
    Lately we discovered the function of this gasket: it insulates the ignition part from the hot crankshaft case. Item #2 is a small deflector (0-ring) that removes oil from the shaft.
    Most gaskets can be made. We even make aluminium gaskets for the cylinder head of the first models.
    Formerly they used to apply some liquid gasket.

    MORE PAPER GASKETS

    Some examples of gaskets we make ourselves are shown on the right.
    Moreover: all kind of metal, viton and teflon gaskets can be made, too.
    That is quite handy, when you face a new type of gasket, that nobody has in stock.

    ALUMINIUM GASKET FOR AV3 AND AV31

    Normally they use a liquid gasket for sealing cylinder and cylinder head.
    But we use an aluminium gasket.... Long ago we had to apply an aluminium gasket for geometric reasons.
    The results were better than expected. So we have used an aluminum gaskets since.
    It can be made out of an AV7 cylinder head gasket.

    AV3 gasket


        V A R I O U S     A R T I C L E S

    HUB BLOCS

    In the hubs of our SP99, 99Z, SP98 and some other "heavy" models you will find a special construction of the rear wheel's hub. Dismounting of the wheel is possible, while the chain and chain wheel will stay in position.

    This construction has also been applied for German Mopeds such as Zundapp.
    For Zundapp there are rubber bushing available, but those are of a minor quality.

    Frank Fr. had this problem and we found out that the Zundapp bushings were too soft. You need rubber with a hardness of 80-90 degrees Shore.
    For rubber this is pretty hard. Finally polyurethan was chosen.

    Next problem for Frank was to process this raw material. Solution was again simple: apply a grinding tool.
    The very first tests on the road were promising. After this job was finished, we heard that in France hub rubber bushings are produced again.
    During the Heerhugowaard fair the checked hardness was not very high. I would prefer the bushings made by Frank.

    Lower picture
    For an other project we had to make 4 new pins, because all were - with a lot of play - connected to the hub. The assembly has been riveted at the hub.
    In this case we could apply the original bushings from Motobécane, made of hard rubber.



    RINGS FOR CHAIN GUARD SCREWS

    Black rings for the well-known chain guard screws are available nowadays, but sometimes people you do not want to apply black rings.
    So one day we made some white ones for a special project. The first ones always will take some time, but after a while the rings can be produced more efficiently.

    chain guard rings

    SPROCKET FOR RELAY-BOX AV92, SP92, SP94TT, SP98 AND 99

    Since we prefer small ones, we had to make those by ourselves.

    At the old worn sprocket all teeth will be removed by way of grinding.
    A new sprocket will adapted on a lathe and all will be welded.
    If you want such a small sprocket do not ask us, but consult a professional company. We just like prototyping.
    On the right you see a sprocket with 12 teeth, which is ready to be welded.


    sprocket

    Special sprocket

    AIRSAL RING

    Airsal is still producing cylinders and pistons for mobylette and of course for a lot of other marques. We use the square 50-cc AV7 on our models, but some long exhausts will give troubles like the exhaust of models SP98 and D52. The copper ring, which seals the connection between exhaust pipe and cylinder can be deformed too much and will be pressed to deep into the cylinder barrel. After a while the exhaust pipe is not sealed anymore and the large gland nut will be loose.

    We solved this problem by putting a thin bronze ring in front of the copper washer. A big radius prevents extra turbulence of the outlet gasses. Thanks to this simple and cheap solution all problems have disappeared now.

    exhaust ring Airsal

    BRAKE PLUG

    A brake plug is a casting in Zamac, which is fixed at the end of the handlebars


    ZAMAC is an acronym for Zinc, Aluminium, Magnesium, and Copper alloy. Casting Zamac is not so complicated. For this foundry process we have use the lost wax casting method. This way of casting is very old: more than 6000 years ago people used this kind of manufacturing.

    After casting some machining is required, because the brake cable will be guided by a bronze bushing, that also is threaded for fixing the plug at the handlebars with a small screw. Zamak is a weak material and a threaded hole is quickly damaged.

    The picture in the middle shows the mould for making the wax model. This model was made of polyester resign.
    The picture at the bottom shows some rough castings.