Making a Pocket Bike Out of TVS Scooty ES

[Mr.Boss]

It started a 4 years ago, http://www.theautomotiveindia.com/forums/two-wheelers/3604-kids-bike-suggestion-required.html
Finally I managed to find time and resource to make it happen now.

Disclaimer:
- This bike will not be taken to public roads.

Base Vehicle Details:
Make : TVS
Model : Scooty ES
Year : 2000

Why Scooty ES?
Scooty ES is the cheapest and safe best. People suggested to get Kinetic Honda or Bajaj Sunny which are available at scrap rates. Those samples I came across were already at their end of life, few rust buckets with bits and pieces of broken plastic around. The subject Scooty is single owner, well maintained and mechanically fit with valid documents. Without a second choice got her and started stripping.

Modifications Planned:
- Length & Height reduction
- Single Seat
- Exhaust routing under the seat
- Fuel tank in the front (Bike like)
- Limiting Top speed (Yet to finalize how to control)

Posting few snaps now. Let me update the progress every evening.

Base vehicle






After 30 mins








Started chopping the unwanted bits & pieces

 

[TSIVipul]

@Mr. Boss:
Why not make a small 4 wheeled buggy out of it? IMO making the mod you are planning requires some serious designing which I doubt that you haven't thought of.

 

[bhvm]

Mr Boss,
Totally hooked to your thread.

You have a very nice donor. Although I was about to suggest the same on your old thread but then I noticed it was 1 year old. Make a quad bike as it will be safer and easer to handle for your child. He won't have to worry about balance.

However now that you have started the project, don't let that dampen your plans.

 

[Mr.Boss]

IMO making the mod you are planning requires some serious designing which I doubt that you haven't thought of.

Can you please eloborate?

Make a quad bike as it will be safer and easer to handle for your child. He won't have to worry about balance.

He is quite good at balancing and he isn't much interested towards Quad bikes now (Situation may change later)

 

[Mr.Boss]

Wheelbase reduced by 200 mm
Chopped the frame and welded






Exhaust routing to be modified. Stock silencer bend will harm the kid's leg

 

[amitpshelke]

Since you are making the wheelbase to be shorter you will require to add more wider tyre to improve stability.

I would suggest to think on how to improve front on rear suspension system. May be dual suspension on back and hydraulic telescopic suspension on front [like bikes].

 

[Mr.Boss]

Since you are making the wheelbase to be shorter you will require to add more wider tyre to improve stability.

I would suggest to think on how to improve front on rear suspension system. May be dual suspension on back and hydraulic telescopic suspension on front [like bikes].

I'm not working on track spec. And stability doesn't depend on wheelbase alone, hope you must have noticed the CG is already lowered

 

[Nanofreak]

Guru Satish,

Salute you for this Chop Shop madness (In a good way), glued, I had the same craze in my teens, my cycle was a rage in lucknow with its wacky designs.

regards

vinod

 

[Mr.Boss]

Proposed exhaust routing

 

[Nanofreak]

Satish,

I think you should look to have the exhaust like the Bajaj Super, under body, as routing it like you have shone, heat shield for the seat, cables etc could be an issue, by the way is this scooty 2stroke or 4stroke?

Modifications Planned:
- Limiting Top speed (Yet to finalize how to control)

I remember when I bought Vijay Super, the accelerator cable at the end before it enters the carb, had a hard plastic which used to act as a speed governor, and at the free service, the mechanic used to sandpaper the same a bit to increase the speed, if you ask a senior mechanic, he will know about this.

regards

vinod

 

[Mr.Boss]

I think you should look to have the exhaust like the Bajaj Super

I had this thought earlier, but the center stand positioning isn't supportive to have a Bajaj Super like exhaust routing. Anyways, let me reconsider if I could manage without bringing it near the seat.

if you ask a senior mechanic, he will know about this.

I'm the Senior Mechanic for this project

 

[incarnation]

Glued to this thread Mr.Boss waiting to see the End result. hope it turns out good. Best of luck

 

[Jerwin]

Absolutely amazing project!
just one question , Is the handle bar height going to be lowered? it looks quite high compared to the seat position.

 

[Lameassonwheels]

Wow. Another amazing project from Boss. Fingers crossed to see the fully painted final outcome. The scooty is in very good condition and I feel you could have kept it as it is, and ripped the engine and frame from some other scooter. Please make sure you are installing support wheels at least for few days as kids won't be familiar with the initial pull of engine.

 

[Akash1886]

Satish, My dear R&D Specialist Another awesome project in progress. From the pics it is evident how much sincere effort has been put by you. Though I have limited knowledge on 2-wheeler but from the looks of it, I can see a superb bike is getting ready. Wonderful indeed!

PS: Have you ever considered Vehicle Restoration as an alternated career choice. I am not joking here! With the kind of acumen you have for 2 Wheeler restorations (Your Bike Restorations being a Testament), I am sure you'll be really successful. Someday, I will surely come to see your creations and restorations in flesh! Till then Best of Luck!

Regards

Akash