megelli resto / rebuild....cheap and cheerful first racer

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

Hello.
New to the forum, thought id share my insanity. but it keeps me out of trouble.....
just recently bought a megelli 125r. Id never heard of them, but they are:
1: pretty big....essential when your 6ft so as not to look like a circus bear
2: really cheap, as nobody has ever heard of them.

I knew it would have loads of cheap crap on it, but at £200 dabs, it was a chance to get back into biking, without a big commitment.

I know there are haters out there, its a toy...chinese crap etc....best bet for you guys is probably read another thread.

But for me, I like tinkering. Im strapped for cash so as always budget is a big/main issue.

ive repainted all the fairing. every tab was snapped off, and there are loads of cracks/bits missing. had to do major surgery on every part as the last owner wanted to streetfighter it and was not bothered about taking parts off carefully.
going to try to copy the sachs minerva colour scheme.
the original exhaust was fooked, and it came with a stainless can. this was under the frame, near the kickstand, and i could see it banging on everything so ive re routed it to under the seat. im making a new tail tidy, as the original plastic job is all cracked and shattered.

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3695_zpsmf2oinzi.jpg

https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3691_zps0dbgzzyk.jpg

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

im re making the tail tidy. I know in the first pic it looks too close to the wheel. its a first fit, ill raise it up when ive checked the measurements.

https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3683_zpshnc7lkbs.jpg
this is made from 40mm mild steel bar, 4mm thick.
its a bit of a jigsaw, but it was from the scrapyards and cheap at a fiver for 8ft of it.

a bit of hope to inspire the build.....a nice painted fairing after major repair....
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3705_zpsedrpxray.jpg

im not doing a list yet as there are a million and 1 jobs.

scored some flexi stainless tube to make an exhaust from had to do it in several pieces, but its really strong, you struggle to bend it over your knee and it wont rust. 3 quid from the scrappy. coincidentally the id is exactly the same as the od of my exhaust....result!
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3697_zpsknjlnbpw.jpg
its routed roughly, but ive got to make all the mounts, couplings and bits to stop it fouling and rattling. going well so far though.
ordered exhaust paste and stainless clips, and some hose for the strange valve on the frame, that recirculates the exhaust.......new to me this modern stuff......it may even start after that!

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

first set up of the new tail tidy. it needs re positioning as its way too low on the wheel. need to trim a bit of the liscence plate holder too, as i welded it a bit wonky. the welds need tidying and holes need drilling for the indicators.
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3707_zpsiob5nsds.jpg
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3708_zpsmdgpdlbi.jpg
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3709_zpsoklfjny7.jpg

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

lots of broke.
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3706_zps16nvuwgs.jpg

picked this up for a tenneroff ebay. mainly wanted the bars as mine were bent, theyre solid ally bar, and i cant straighten them without calling upon wodin of the dark forest. Its already paid for itself as i found that my yolks had sheared bolts in the thread.....result!

https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/iug_zpsh0gd2gdt.jpg

5 new tabs of abs glued on and repainted before the white vinyl is applied.
using rustoleum hard hat, i recommend it, gret coverage, and ultra hard when its cured. it needs laquer for a good shine, i may or may not do that, its to early to be bothered yet.
THe glue, toluene based is not working great onder load. im finding thats its much better heating a knife and melting the parts together, befor covering the gouges with a flexible filler.
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/IMG_3711_zpsyd7uf8an.jpg

Todays work so far.

screen was scratched and crazed. all the lugs were missing. remade them from abs, araldited them on and fiberglassed it smooth. fortunately the sachs colour scheme has a red visor, so i dont mind. plus, the visor is so low, id never be looking through it unless i had my chin on the tank.

The belly pan had a large piece missing, the area that covers the stand, so i cut the cracked bit off and rounded it out. at least 5 big cracks in this so its got a lot of abs and filler. it will need more filler......really it was only fit for the bin, but i cant find another thats not in australia, and the shipping is way too much...so repair it is.
tail tidy needs re shaping as i was tired last night welding it up, and its a bit out of line, but a thin cutting disc will make short work of that. needs holes for the indicators, but my current drill set only goes to 6mm, (over that are all blunt-really blunt) so i need to get a bigger set.
https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/2015-12-18%2015.01.20_zps5qdb9oie.jpg

https://i1277.photobucket.com/albums/y495/VOLKSWAGONCAMPERPIX/2015-12-18%2015.02.03_zpsrkslryan.jpg

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

Another full day of flatting, paint reactions, more flatting, more paint reactions, a bit of melted plastic- tried every type of glue on this abs, and the best way so far is getting a sheet of abs from ebay, cutting it into thin strips, and hot knifing it into the cracks. it will sand, and has a surprisingly strong grip. just fixed 2 four inch cracks on the mudguard, and its stronger than the original now.

MarJay · But it's British! Joined: 15 Sep 2003 Karma :

You're going to race a four stroke 125? Question

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Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

mattsprattuk · Super Spammer Joined: 12 Mar 2007 Karma :

Megelli isn't cheap because nobody's heard of them... But you'll find this out soon enough.
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Kickstart wrote: Hi I tend to agree with Matt. All the best Keith

Jaco · Two Stroke Sniffer Joined: 01 Apr 2014 Karma :

Had one of these as my first geared bike. I felt cool as fuck on it but it was such a fucking pain in the arse. Could never leave the house without a backpack of tools on me. Coming up the A38 one time and the exhaust was gradually getting louder and louder. Didn't bother pulling over to check it out because it was raining and I was cold and only a few miles from home. Anyways a couple more miles down the road I feel a hefty whack on the back of my boot. Pulled over the the side of the road to find that the middle section of the exhaust had come loose and swung ninety degrees and was perpendicular across the bike Shocked

Pretty bike though.

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

which is the main reason im going through it replacing anything i find thats not up to scratch.
most of the fixings are stainless, and im machining anything that needs redesigning.
i may be wrong, but as a frame forks and swingarm, i cant see any problem with this as a basis for a project. anything else, i can replace, or repair. shouldnt really matter that people dont have a high regard for them, it works our better for me when im buying parts.........
also, i do love an underdog...... Razz

pepperami · Super Spammer Joined: 17 Jan 2010 Karma :

Good stuff Thumbs Up

more please, with pictures Thumbs Up

When you tell us about how you fixed the cracks in the plastics, can you put up some pics as you do it please.
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Fidge · Banned Joined: 04 Oct 2014 Karma :

Looks good Thumbs Up

hope you complete it and post a few vids.

DRZ4Hunned · World Chat Champion Joined: 15 Apr 2014 Karma :

I like the ingenuity of using that SS flex-pipe stuff to make an under-seat exhaust, looks like it has plenty of potential Thumbs Up

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oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

thanks for the replies chaps.

ok, ive been fiddling with the egr valve. i was considering blanking it off, but seeing as i dont relly know how it behaves, i thought id at least take it to bits.

i did this because all the pipes had hardened to a point where they just snapped off when i moved them, so some repair was needed.

luckily i had 2, although one was surprisingly different conditionwise, seeing as they are both from 2009 bikes.

ive put the bits in brake cleaner +DONT DO THIS+ the cleaner eats away anything rubber, as i found. the seals swelled to nearly double there size. luckily i could clean up the others .

https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3719_zpsoif5kk2l.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3721_zpspbzdgtn7.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3724_zpsdfllx1jr.jpg

even cleaned, this part is damagede, not as bad as the 2nd, so ive had to use it. not sure what it does or if it matters.

https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3726_zpsc4m3bfri.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3727_zpsx6uvwnqq.jpg

a bit of vht paint

https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3729_zps8hetlig5.jpg

new stainless fuel clips and high pressure lines with a red racing stripe!

https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3732_zpsp8xuah4u.jpg

carb looks like it been replaced. ill give it a clean and see whats what.
https://img.photobucket.com/albums/v260/oberonspacefruit/IMG_3734_zps09r0iafp.jpg

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

almost started today! Very Happy

i bought new plug, put on new silicone vacuum hose, with clips, replaced the fuel hose, atatched the egr valve.
charged the battery.
nothing.

first i was having problems fueling the carb.

it runs when you spray brake cleaner in the cylinder with the carb off.

carb is still not filling properly. vacuum line is working.

drained the carb onto a piece of tissue.
set fire to it.
it burned everywhere exceptwhere the "fuel" was.

it seems the tank is taking on water, so ive fitted a new rubber seal.
cleaned and drined the tank, its nearly impossible to get all the fuel out, as the drain hole still leaves a little bit in. i ended up stuffing a big wad of bog roll in the filler and shaking the hell out of it, s to see if it got wet. replace the wad repeat, until no moisture on the wad.
cleaned all the fuel tap and filter in the tank. fitted a new petcock seal.

not sure the carb is fueling properly. when i drain it it sometimes is empty. need to keep an eye on that......all the lines are new......carb is clean so it should fill ok.......

anyway after a few tries it started badly, ran while i kept my hand on the throttle, at low revs. it was loud so i turned it off. started it a few more times then the battery gave out.
got to rate that as a sucess, even though its running like shit.

ive set the mix screw to 1 and a half turns from tight.

due to the new exhaust, im thinking it needs re jetting.

not sure how to do this effectively, i can see how you replace the jets, but i dont know what else to change/adjust.

I may just take it to the shop, now its nearly running, unless i get some brilliant solutions on here......

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

ok, heres how ive been doing the plastics. this is the crack.
https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0004_zpsvsy5fpo0.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0005_zpscnu8jmhv.jpg

got a sheet of abs of ebay for about a fiver. Ive found the best way is to cut it into thin strips, for melting into the gap.
https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0006_zpsatdtgvqz.jpg
heat up a knife on the gas, it needs to be really hot, and you can only use it for about 5 seconds at a time.
https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0007_zpstupmd5i2.jpg
cut into the crack with a saw blade, or dremmel or whatever youve got. the point is to open it up and clean it from the oil and crap thats bound to be in it. i try to make other cross marks to remove some more material, before going in with the knife.
https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0013_zpsxltvkfof.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0016_zpsm94inp4z.jpg
the idea is to spread the existing plasic around a bit so your not just filling a 1mm crack, as the new plastic will be weaker. try to get a decent size crater, spread it about a bit and your already taking the stress away from the original crack.
https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0018_zps3mseqcjz.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0019_zpsrakfqzpa.jpg

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

orac · World Chat Champion Joined: 25 Sep 2011 Karma :

you need to buy yourself a gas powered soldering iron.
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pepperami · Super Spammer Joined: 17 Jan 2010 Karma :

Thank you Mr Spacefruit Thumbs Up

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oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

oberonspacefr... · Nova Slayer Joined: 17 Dec 2015 Karma :

ive finally got the wiring to a reasonable working state.
it was absolutely fooked......every kind of household connector and bodge.
stripped all the tape off and drew my own wiring diagram, which took ages but will help with future diagnosis.
soldered new vehicle multiblocks on nearly every connection, im left with one block of assorted mystery, mostly dash stuff i think.
shrink wrapped everything i could fit shrink wrap. new connectors on verything that wasnt in a block.
https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0218_zpsgy8nwdct.jpg

fitted the undertray dirt shield thing. had to cut a lot out to fit the stainless can. I may rebuild this up yet, if it has lost its sheilding properties.

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0220_zpsw1swbtpr.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0217_zpsgsuldx6w.jpg

re soldered the starter lead, it was worn through, an about 5 times longer than it needed to be. theres enough crap under there without unecessary stuff as well.....

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0214_zpsvuse1vn9.jpg

replaced every bolt i can see with stainless.

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0215_zps1vyeofne.jpg

made this tail tidy. it needs more work, as its not got a thread for the indicators, any mounts for numberplate, or any route for the wires.
its just a device to get to the right area with the minimumum of bulk.
its made from steel bar and a bit of plate. ive blacked it to stop it rusting while i continue to mod it.

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0221_zpsxuplpxtm.jpg

https://img.photobucket.com/albums/v260/oberonspacefruit/DSC_0235_zpsd1kigeha.jpg
its landed in roughly the right place. i have a bit of adjustment for height by the way its mounted. needs a plate on it somehow before i adjust it.

re painted the plastics on the tail. took a chunk out of it within 20 mins.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Tidy! Good work!
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Nexus Icon · World Chat Champion Joined: 26 Aug 2010 Karma :

It looks promising.

I'd be so tempted to stubby the exhaust can to get it back nearer the end of the tailpiece but it might make it sound ridiculous.
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