Wassell Restoration

[iyaoyas]

Based on my research within this forum I understand that some Wassell engines were reworked by Penton Imports to increase displacement from 125 to 152cc. I have a Wassell (W373 ST) configured with the Sachs engine but with Penton decals in place of the Sachs embossed logos on the cases.  Additionally, my cylinder is cast iron but the head is aluminum.  

Is there any traceability as to which bikes, by s/n, were reworked?  Does the iron cylinder indicate a reworked engine?  What is the reasoning for specifying the iron vs. aluminum cyl's.?

Also, can anyone recommend a good 'bodyman' to repair/re-shape the aluminum fuel tank? I would consider buying a nice used tank if available...

Thanks-

[Lew Mayer]

I have heard of a place in Canada that does nice restoration of aluminum tanks but I'd have to get the name from a buddy of mine.

Lew Mayer

[iyaoyas]

Thanks Lew-

[Paul Danik]

I don't think you will find a registry from "back in the day" that will show what engines were converted to 152cc.

Most all of the 152cc engines were converted from cast iron cylinders, but there are a few aluminum cylinder 152cc engines around. There are a few "hints" that a cast iron Sachs engine may be 152cc, the first is if it has the higher compression head instead of the butch style head, the link below will show you one of the hi-compression heads. The head is not a sure fire indicator, but the kits that Penton sold thru their exchange program mostly, if not always, used the hi-comp head. You can see those kits in some of the Hi-Point catalogs. On my first trip to Amherst, as were getting ready to head back home with my repaired Penton, John gave me a box with one of those kits in it and stating that he felt I would be impressed with the increased performance, and as usual..he was right

http://www.pentonusa.org/steeltank/regviews/steeltank13b.jpg

The other item to look for is a thinner base plate on the cylinder as the Yamaha 305 piston, which was used in the early 152cc engines, had a wrist pin location that required that the base of the cylinder be milled to obtain the correct deck height. The later Weisco 152cc pistons were designed with a wrist pin location that didn't require the cylinder base to be milled and with a wrist pin the same size as the Sachs wrist pin. This is also why only the aluminum rod could be  used with the Yamaha piston as it had a top end bushing that could be reamed for the larger Yamaha wrist pin, the steel rods have a needle bearing. If you look at a milled and an un-milled cylinder together you can notice the difference.

It isn't hard to unbolt the head and take a peak if needed, but if you are scouting out a bike at a swapmeet sometimes you don't want to show all your cards, or so I am told...

Maybe a bit more than you asked about, maybe not...

Hope this helps,
Paul

[seanguthrie]

Paul, I always love your insight on these matters.

74 250 Hare scramble
73 CMF 6day
68 6day V213

[iyaoyas]

Thanks Paul-  Based on the image in the link you provided, I can confirm I do not have the high compression head.  

Here's a few pic's. of the 'project' as it stands today...



Ouch...!  Broken Cylinder fin...will need to find a "specialist" to repair this 'issue'


View from the right side...


Cylinder Head - Aluminum




Crud in the intake...


Exhaust Port...Aluminum, Iron & moisture do not play well together...


Fuel Tank

[3putt]

iyaoyas,   Send me a  note off list, I may be able to help you out.  My mail address is 3puttathky.com.   wnm

[3putt]

iyaoyas,   Send me a  note off list, I may be able to help you out.  My mail address is 3puttathky.com.   wnm

[iyaoyas]

Hi 3putt-  

I don't recognize the e-mail address format you gave me so I sent you an e-mail with my phone # through the POG forum.  

You may also reply to: [email protected]

Thanks-

[iyaoyas]

Okay, 3 hours later and here's all I've got to show for it [V]





Most of this time was spent on removing the IRON cylinder...almost there






Was the rear brake switch added by Penton Imports or an enthusiast?


Okay...what's wrong with this picture??




The seat pan is salvageable...this is good!




Hahahaha...!  Improvise, overcome & adapt...man vs. oxidation-


 

[Gordon Brennan]

Stephen,
You've got your hands full.
As far as the tank goes, you can go on youtube and search 'removing dents from aluminum tanks'. I know of a guy that used to charge around $75.00 for an average tank. More fun to do it yourself though. An old screw driver rounded over or a ball driver bent to reach the dent at a 90 degree angle and a propane torch. Heat the aluminum from the outside while simultaneously working the dent from the inside with the ball driver.
Not sure you really need the 152cc change. I compete with mine at 125cc and it works fine. You'll have some carburetor adjustments to due as well if you change it. What size is the carb on it now?
You will need a bigger rear sprocket I think. That one seems a little small for Trials. Forks look good. That front tire is exactly what mine had on it when I got it.
What are your plans for it? Trials or Trails?

[desmond197]

Joe Abbate from Cycle Therapy does majic on Al tanks

[Lew Mayer]

From my experience, if I had to do it over, I would stay with a 125cc and find the high compression head.

Lew Mayer

[firstturn]

Listen to Lew.

Ron Carbaugh

[iyaoyas]

Thanks for all the advice fellas.  I think I will retain the 125cc configuration.  My Cylinder is trashed and seeing that there's no oil in the crankcase I'll likely have to rebuild my  crankshaft assy. as well.  Let's hope the steel connecting rod is straight!  

I sent an e-mail to the folks at Joe Abbate's Cycle Therapy requesting a quote and lead time for repairing my tank.  I typically do all my own work but over the years I've learned my limits and know when to call for help...

Soon I'll compile my parts list...my goal is to have this project completed for the VMD @ Mid-O this summer

Finally removed the cylinder!


'Dry as a Bone' inside the crankcase...


Neglect...


Steel Connecting Rod...


Bing Carb...