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Honda Aero 50 resto thread.
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I recently came across a honda aero 50 on craigslist. the guy wanted $400 but the bike was a bit beat up and non-running. we settled on $200
i went back through this thread and it's pretty random and unorganized so bare with me haha Attachment 444428 Attachment 444429 Attachment 444430 first things first i got the plastics off to start inspecting the engine. Attachment 444431 quite a bit of dirt the first issue i found ( and proof the guy that i bought the bike was lying to me that it ran fine) was some bad wiring Attachment 444432 Attachment 444433 not exactly sure why, my assumption is someone twisted some wires together to repair a broken one and it grounded out and melted a bunch of them. Attachment 444434 one of the belt/ variator cover hardware was stripped to crazy so i had to hammer a smaller socket onto it to get it off Attachment 444435 i believe this hole is where a kick starter used to be.. wish i still had it... Attachment 444436 overall nothing too bad so far Attachment 444437 i'm going to recreate these stickers in adobe illustrator so i have brand new ones! Attachment 444438 the floor board is going to take some serious love to get black again... Attachment 444439 Attachment 444440 i think the thing looks pretty cool without the plastics Attachment 444441 got the suspension off to clean up the motor Attachment 444442 how low can you go? Attachment 444443 the variator weights have bald spots on them i'm sure they haven't even been inspected sense they went in during manufacture.. i hope i can finds some new ones Attachment 444444 Attachment 444445 this is where i ended the first night |
Re: Honda Aero 50 resto thread.
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day 2
Attachment 444419 quite a bit of dirt on the inside of the wheel Attachment 444420 engine out Attachment 444421 this is the ONLY plastic piece on the bike that isnt broken HAHA Attachment 444422 front cover off, this is about all i can to other then the front wheel with the tools i have. Attachment 444423 wheel has rust inside i wonder how often the tires were changed in this bike's life Attachment 444424 i wish i would have taken before pictures, one of these brake handles was bent but i used a hammer to straighten it Attachment 444425 Attachment 444426 Attachment 444427 end of the day i cleaned up and lay'd everything out "exploded view diagram" style (kindof) next i need to decide what i'm going to have powdercoated and what i need to order to get this thing back on the road |
Re: Honda Aero 50 resto thread.
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today was motor day! i dis-assembled the thing and checked the tolerances on everything.. after a few hours of cleaning dirt and carbon this is what I've ended up with...
Attachment 444358 i also cleaned the starter/oil injector and the associated bracketry Attachment 444359 the spark plug still needs replacement, i just have the guy blocking the hole from foreign material Attachment 444360 Attachment 444361 i also cleaned all the blue plastics and used some armor all on them to get them looking nice and blue again Attachment 444362 engine mount before (but after cleaning) Attachment 444363 mount after Attachment 444364 the engine cover is stupid dirty and is taking quite a while to get clean... Attachment 444365 painted the exhaust heat-shield with a high temp dull aluminum paint Attachment 444366 the wiring is gonna be a nightmare! Attachment 444367 like i mentioned before i think the problem was someone did a ghetto job with the harness... Attachment 444368 here is my evidence and the reason the ground wires were mostly melted and shit...damn wire twisters that's about all i have for today more soon! |
Re: Honda Aero 50 resto thread.
In for the finished product! Cool build man.
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Re: Honda Aero 50 resto thread.
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Originally Posted by Tuner Eddy
(Post 47781340)
In for the finished product! Cool build man.
i've been working on that shit harness. each day gets me a bit closer to getting this guy started ( i cant WAIT to ride it!) i've recently purchased some spraypaint for the frame... it's fairly close to the OEM paint but still a bit light.. it wont matter when the plastics are installed anyway... Attachment 444258 I also have finished the layout for reproduction front sticker (the colors are not finalized yet) Attachment 444259 i still have to match them to my pantone swatches but they are almost there ( the "e" is slightly different but the other letters are practically spot on! the black line around the thing is the cut path, and the yellowish white square is the actual picture i took previously) i also ordered a new belt and rollers yesterday.., this weekend i hope to get the wheels powder-coated and the tires ordered |
Re: Honda Aero 50 resto thread.
This thread makes me want to find a old scooter to restore! :)
How hard is it to the oem Honda parts for something this old? |
Re: Honda Aero 50 resto thread.
Originally Posted by JDM-sol 89
(Post 47799194)
This thread makes me want to find a old scooter to restore! :)
How hard is it to the oem Honda parts for something this old? if you are really interested check out this forum for more http://www.hondaspree.net/phpBB3/index.php |
Re: Honda Aero 50 resto thread.
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got these in today
Attachment 444121 put them on Attachment 444122 that is all (been pretty busy lately) |
Re: Honda Aero 50 resto thread.
What camera are you using to take your pictures? Shots are extremely clear.
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Re: Honda Aero 50 resto thread.
^ all but the first three were taken with a Nikon d90 w/the kit lens they are all straight off the camera (none of them have been edited)
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Re: Honda Aero 50 resto thread.
The quality is amazing. I'm trying to find a good camera to invest in for I ever get deployed in the future
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Re: Honda Aero 50 resto thread.
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Originally Posted by JDM-sol 89
(Post 47836041)
The quality is amazing. I'm trying to find a good camera to invest in for I ever get deployed in the future
http://kenrockwell.com/ for plenty of info on them, honestly i've spent hours on the site this weekend i put the motor back together and mounted it back on the bike, i decided not to paint the frame until i ensure the motor is running i dont mind taking the bike apart again, but i'm more motivated to ride the bike then to get it looking perfect at the moment Attachment 444056 Attachment 444057 Attachment 444058 next is to get the harness situated, the battery charged, and to do a bit of rust removal on the inside of the tank, then the moment of truth! |
Re: Honda Aero 50 resto thread.
What are your plans for stripping the frame down? Are you going to get it sand blasted or are you going to wire wheel/ sand it down by hand?
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Re: Honda Aero 50 resto thread.
Originally Posted by JDM-sol 89
(Post 47861181)
What are your plans for stripping the frame down? Are you going to get it sand blasted or are you going to wire wheel/ sand it down by hand?
got a few things accomplished today... first i repared some of the cracks with some plastic filler (clear) i'm trying this stuff for the first time so we'll see how it holds here is a before/after of a slightly polished rear tail https://imageshack.us/a/img189/3617/014in.jpg here is the slightly modified air filter https://imageshack.us/a/img805/2213/016cu.jpg https://imageshack.us/a/img155/3580/017iav.jpg cleaned up most of the rear plastics https://imageshack.us/a/img577/6993/018uv.jpg https://imageshack.us/a/img805/1216/020iz.jpg https://imageshack.us/a/img27/6676/024kgc.jpg doesnt look like much from the outside but i used the penny/solvent trick to get the gas tank de-rustified clean and dry and ready for some fuel! https://imageshack.us/a/img585/866/026qt.jpg at the end of the day i mounted the seat.. if all goes well i'll finish the harness, ( the battery is charging as I type) fill the tank and, take it for a spin (knock on wood) https://imageshack.us/a/img685/4765/029cy.jpg |
Re: Honda Aero 50 resto thread.
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i found an 84 honda elite 125cc on craigslist for cheap (almost free cheap) the bike was in a fire so a lot of the plastics are melted but the motor only has like 4000 miles on it! the wiring is all good and when i pulled the variator the rollers were not even worn. i'm seriously debating putting that motor on the aero, only issue would be finding a place to mount the radiator and fabricating the engine mount and shock mounting locations. i'm going to finish up with the 50 cc motor and enjoy the bike for a while first ( might not even do the swap) but i'm thinking that would be a pretty awesome project.
Attachment 443966 ^the 125cc motor |
Re: Honda Aero 50 resto thread.
lookin good!
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Re: Honda Aero 50 resto thread.
Nice aero 50. Looking at yours makes me miss my aero 50 that i had couples years ago.If i was you i would get a bigger bore,carb exhaust etc for the motor.
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Re: Honda Aero 50 resto thread.
^ i cant find much for the aero. i understand it shares things with the spree and few other models of scooters.. i think the 125 motor would be the shit but dont know how much i want to do with it
this thing has just been playing musical chairs in the garage.. have some time off coming up soon. maybe i can do some work on it |
Re: Honda Aero 50 resto thread.
Really enjoy following this. You are doing a great job.
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Re: Honda Aero 50 resto thread.
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been a while.. decided to go ahead and put the 125 motor in... havnt done more then this yet though. been working on my other scooters a lot. got my metro running great with a better filter and jets. and my reflex got a bunch of polini stuff for the drivetrain..good stuff
Attachment 442284 need to design the engine mount, then find a fabricator/wielder |
Re: Honda Aero 50 resto thread.
bump for an update.
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Re: Honda Aero 50 resto thread.
6 Attachment(s)
^alright, nothing too different
Attachment 441880 after about 2 weeks of debating what/how i was going to mount this engine i decided on the spot pictured above using the oem mounts welded to each-other at an angle that avoids the starter. this also leaves enough for the carb and the filter/velocity stack. the cool thing is the plastics have a vent that is in-line with where the carb faces on the right side. Attachment 441881 the suspension will be mounted to the back here^ the best part about this is the oem plastics will only need a small amount of trimming on the back side to avoid the shocks so it will look very similar to OEM Attachment 441882 here is a view from the other side Attachment 441883 and where the shock will be mounted on that side this side will require about half of the inside of the storage box to be cut off. other then that there will be little required modification to the fairings to get it to work. because the oem throttle cable wont work with this set up ( it had the dual version that works the choke and the carb's butterfly valve(?)) i ordered the cable for the elite 125 (dunno WHERE mine is) here is a front-ish and back view of where the motor sits... Attachment 441884 Attachment 441885 once i get the mount welded the 2 biggest problems are going to be where i put the radiator and the wiring (that i usually have to just wing or call someone that knows what they are doing) |
Re: Honda Aero 50 resto thread.
Nice job man some really good work! Puts a smile on my face when people take such care in repairing their Honda's. I have two Spree's that I've been working on a bit this winter. Nice garage too!
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Re: Honda Aero 50 resto thread.
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Attachment 441553
not really that much of an accomplishment, but today i cut my engine mounts to prep for the creation of the custom one...still need to do some grinding.. but soon will come the welding |
Re: Honda Aero 50 resto thread.
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spent a couple hours (and a couple beers) sanding the paint off the plastics...(FYI... sanding is probably my least favorite thing to do) after i get all the paint off i'm going to try and repair all the cracks and fill in the few deep scratches.
if anyone knows about some stuff that is perfect for that let me know so i can buy it. otherwise i'm going to try this plastic weld stuff that i bought at auto zone. here is where i stopped for the day. the headlight cover is practically finished the rest still needs some work ( as i'm sure you can see plainly with your own eyes) Attachment 441424 |
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