Millenium Aero

[devenex]

This project involves a poor neglected '85 Aero that I bought off Craigslist for $50. I'll be swapping an af16e motor from a 2001 Elite onto it as well as restoring some hacked electrical and damaged/missing panels.

Day it was picked up
Front (note no blinkers):


Didn't have rear plastics then:


Suspiciously stock black under headlight:


Motor pics:
No exhaust, carb or wheel on:


Other side:

[devenex]

Previously done work: Cleaning and engine removal, sorry no pics for this. Also forgot to say everything will be clickable thumbs, you're welcome one remaining 56k guy

Work done today: Installed keyed ignition and changed out lock on glove box to match. Parts for this purchased from wheelman-111, Flash lives on! Also removed stock engine plugs and soldered af16e plug in its place. Cut the "new" plug from a harness I bought off eliteguy50.

No motor!:


Or Front!:


Flash transplants:


"New" motor plug:


Those went great but I also have to swap the CDI + connector from the elite harness onto the Aero. Orange circles are over the cut wires (visible ones in the pic anyway) for the CDI. I want to verify that red arrow points where coil sits (waiting on mine to come in mail, so can't physically check yet) and that pink arrow points where CDI sits (Elite one is slightly smaller, but fits there). Can anyone tell me if I'm right? (Must click thumbnail to see what I drew on for some reason)


Also have a broken exhaust mount bolt on the motor that I can't get out myself. Broke my easy out! Probably have to take this to a shop

[Wheelman-111]

Greetings:

I'm following this build with interest.

Oh no, the broken bolt blues! Something to turn a three-minute disassembly into a three-hour ordeal. Aluminum corroding around steel can be pretty bad. I wish I had rememembered to slather some Nev-R-Seize on every such interface, including the spark plug - were it not for the fact that it comes out every couple hours...

Breaking a hardened tool in the bolt adds a level of complexity. That leaves heating the crankcase and perhaps welding a grippable extension to the bolt... Sorry for your struggles.

[devenex]

In my case the motor came with it. Don't believe the ebay seller mentioned it either. I don't have a torch, welder or welding skills, so looks like someone will make some $$$ from this. Still worth it to me though

Now I panned through the manual last night and know where to put the CDI ( I was right w/ the pink arrow) but the red arrow was wrong. That part is for routing wires, apparently the coil goes on the Aero's airbox (aer-box ). No big deal to find a new spot for that though.

What I am wondering about is whether the Elite airbox will fit under the Aero plastics. When wheelman tested his stock elite he found that a uni filter just added noise and dropped top speed a smidge, making me rethink my plan to use a unifilter and up-jet accordingly. Anyone have a solid answer for me?

[Wheelman-111]

Greetings:

The Uni did not work as well as the stock airbox at 50cc. With a bore kit, I was unable to find acceptable jetting using the stock box.

The Elite box should fit behind the Aero's panels. If you stay at 50cc jet up to 82. Maybe 85 with gears and a vario.

[devenex]

Thx Wheelman! I'll go for the box then, as the plan is to stay w/ stock cylinder.

I have an OKO variator for it and the exhaust will be Jesse's old 26mm R1. I'll see how it runs w/ stock gearing first, as I do need to climb a hill from time to time.

[devenex]

Just spent the past 2 days cleaning out a petcock I got off ebay. Was clogged with rust/mud all the way to the threads , but its clear now and the diaphragm dis-engages under vacuum. Simply amazing what paper clips, q-tips and gasoline can accomplish.

No real exciting pics for that, but because I don't like to update w/o pics here some other things to take a looksy at...

Jesse's old R1 and a chrome kickstart lever purchased from bakaracer:


OKO variator and roller pack that came w/ it:

[JoshKamp330]

Awesome job. Looks like mine when I got it. Keep us posted

[Spreetard]

i'm jealous of you areo owners, the dio fits better under the body than sprees.

[bradthreee]

I've got Flash's heart beating in my Spree

[Wheelman-111]

Greetings:

So Flash lives again? I must've missed it. I'd be interested in your top speed in a frame that's 35 pounds lighter! Can you GPS and tell?

[bradthreee]

Something tells me it'll not be much different as I weigh at least 35lbs more than you

[Wheelman-111]

Greetings:

Quoth B-Three:

Something tells me it'll not be much different as I weigh at least 35lbs more than you

Ah, but not for long:

Wheelman's Guide to Fighting Wrinkles Through Obesity
- Available at fine bookstores and on Amazon.com.

See Chapter 3: The All-Butter and Vodka Diet

[odinxxix]

wheelman make sure you can hold the bottle of vodka after handeling that butter. LOL cant wait to see the final product, i like those aeros just cant find one here that is in good enuff shape to even work on. last one i found had piston melted in to the cylinder, was a mess chunks and chips all up in there.

[devenex]

Well if you can find an Aero w/ complete body panels you'd start ahead of where I did. Regardless of how bad the motor was (you can almost always get a good deal on an af05). As for this little guy, I don't know if the original motor ran, but currently its just sitting in my closet as I have bigger plans