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General Category => Bike Builds, Rebuilds And Restorations Only => Topic started by: Canuck750 on September 17, 2021, 08:56:59 PM

Title: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 17, 2021, 08:56:59 PM
I have been interested in the early 60's Aermacchi European models for a long time, prior to Harley Davidson aquiring the controlling share of Aermacchi in 1960 the Italian bike builder had a range of 175cc and 250cc models all based on the same horizontal single four stroke.
Prior to the now familiar single Aermacchi produced a range of small discplacement bikes under the design lead of none other than Lino Tonti.

After Tonti left for FB Mondial it was Alfredo Bianchi that designed the familiar horizontal single. The first motorcycle to carry the lovely single was the futuristic 'Chimera'

(https://i.postimg.cc/kgwWQdLG/Aermacchi-250-a.png) (https://postimages.org/)

as cool as it was, described as a jet engine with a wheel at each end sales were dissapointing. Bianchi redesigned the motorcycle by stripping off the futuristic cowling and ditching the single sided swing arm to offer the 'Wing' range of bikes, 175cc Ala Rossa (red wing), 250cc Ala Azzura (blue wing), 250 cc Ala Verde (green wing) and the over the counter race bike 250cc Ala d'Oro (gold wing).

In 1961 Harley Davidson imported the Ala Azzura (blue wing) under the name Wisconsin, in 1962 it was sold as the Sprint

(https://i.postimg.cc/K8mn3YqC/harley-spirit-sq-jpg.jpg) (https://postimages.org/)

The Ala Verde was not imported to North America, it had a long steel tank, clip on handle bars, 17" wheels and a sporty hump back seat.

I am building a replica of the early Ala Verde, as lose to stock as possible. Ala Verde parts are very hard to find.

(https://i.postimg.cc/QtKxRvj9/ala-verde.jpg) (https://postimages.org/)

I am starting with a 1966 Harley / Aermacchi  frame and swing arm, this bike had been in a fire and came with no engine and a rear wheel from a 350cc moto cross model. I won't be using the original Sprint gas tank, the big rear wheel or the flat wide seat pan.

I found a H motor for a 1965 a couple years ago and fully rebuilt it, found the correct carb and heel / toe shifter. I am on the hunt for an engine side cover that has 'Aermacchi' cast in the side along with 'Harley Davidson', I saw one a year ago on Ebay and should have bought it then :thewife:

(https://i.postimg.cc/50XsGb1k/407-BD93-E-88-E1-4585-814-B-905-DE8680-DE4.jpg) (https://postimg.cc/PpkbvGCm)

I was lucky to find Leslie Bull of Moto Italia in California, Leslie supplied me with an Ala Verde gas tank, the foot pegs, a rear wheel from a 1961 Sprint and the lower forks castings unique to the 1961 . I found the upper fork shrouds and tripple clamp on UK Ebay.

These forks are not correct they are off a post 67' Sprint and are for an 18" front wheel.

(https://i.postimg.cc/qMwLHY8R/624-BCB79-441-B-4965-9-FA2-3271-CD3653-C6.jpg) (https://postimg.cc/zVLWnx2Z)

These are the correct forks and tripple and are for a 17" wheel,I put them together this afternoon

(https://i.postimg.cc/htrWZHMN/072-C6-A42-08-E9-4-F6-D-91-B3-B233-ABEDD7-C5.jpg) (https://postimg.cc/xXc4cpwP)

I cut down the 67' forks by 32mm in my lathe and re-cut the lower snap ring into the tubes and bored out the base of the tubes for the damper rod stop. I made new replica chrome lower shrouds from 304 stainless steel thin wall tube,

Trimming the stainless tube over an aluminum slug and a wrap of copper sheet to protect the stainless surface

(https://i.postimg.cc/R0pr4KkR/ED3-F97-D2-CCBA-426-D-9-ECC-25-C23052-B4-B8.jpg) (https://postimg.cc/DWGpcJyJ)

(https://i.postimg.cc/W4THGxSy/97-A4-E11-A-73-CC-4-AB5-B9-A9-1-C8-D8-E8111-CF.jpg) (https://postimg.cc/hXZsgyk8)

the stainless slid perectly over the fork lowers and a wee bit of epoxy will permanently secure them once the parts are painted.

The headlight is NOS and model crrect from Santo di Motorcycle, the Benelli go to guy on Ebay,

(https://i.postimg.cc/t4yG5Xdh/6-AF364-CA-B4-B0-4242-8693-885409-EEFB95.jpg) (https://postimg.cc/mtdnZW5D)

I found a used Aermacchi Ala Verde seat base on Italian Ebay this week and I had previously sourced a correct repro seat cover from Italy as well. I found a repro Ala Verde header and muffler in Italy and the correct decals for the tank and tool box.

The rear fender I have is not quite correct and will need to have the brackets repositioned and some holes filled in, new ones made. The front fender is very hard to find, I am going to start with a Benelli front fender of similar vintage and style and rework the fixings.

I don't realy like the handle bars bars I found, too narrow, I will cut them in half, weld in a slug and widen them.

The front hub is off a Honda CB450 Black Bomber 2ls brake and a popular upgrade in the day for racing an Aermacchi, I will have Buchannans supply spokes and a new rim.

Many, many things to find, build and repair, its going to be a slow process.
Title: Re: Littel Green Wing - Aermacchi Ala Verde
Post by: cliffrod on September 17, 2021, 09:03:27 PM
I'm ALL in for this build, Jim. 

Those early Aermacchi bikes are a real special soft spot for me.  A friend in Knoxville (the one that got my old HD Sidecar body) had a complete 61/62 that drove me nuts for years.  He would not let me own it.   Maybe your bike can bring me some vicarious resolution.  I know it will be fantastic.  I'll be watching.....
Title: Re: Littel Green Wing - Aermacchi Ala Verde
Post by: Michael Moore on September 17, 2021, 09:34:13 PM
You might enjoy a couple of photos of my friend Jim's Tony Foale-framed 350 racer that were taken at Willow Springs
(https://i.ibb.co/k9QKYP2/Start-Build04.jpg) (https://ibb.co/k9QKYP2)
:


(https://i.ibb.co/S5x5BjD/IF5B7315.jpg) (https://ibb.co/S5x5BjD)

(https://i.ibb.co/HqkPXmS/IF5B7318.jpg) (https://ibb.co/HqkPXmS)

(https://i.ibb.co/0srwgyy/IF5B7320.jpg) (https://ibb.co/0srwgyy)

share images free (https://imgbb.com/)
Title: Re: Littel Green Wing - Aermacchi Ala Verde
Post by: Frenchfrog on September 18, 2021, 06:25:20 AM
Lucky man ! I love those machines but sadly nearly everyone that comes up for sale over here is well above a reasonable price. I'm going to follow this rebuild like all of you previous immaculate ones !
Title: Re: Littel Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 18, 2021, 09:13:03 AM
You might enjoy a couple of photos of my friend Jim's Tony Foale-framed 350 racer that were taken at Willow Springs
(https://i.ibb.co/k9QKYP2/Start-Build04.jpg) (https://ibb.co/k9QKYP2)
:

Wow that is one special Aermacchi, amazing frame on that red rocket! Thanks for the pictures.
Jim
Title: Re: Littel Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 18, 2021, 09:16:51 AM
Lucky man ! I love those machines but sadly nearly everyone that comes up for sale over here is well above a reasonable price. I'm going to follow this rebuild like all of you previous immaculate ones !

Thanks French, I would never be able to get a real Ala Verde so this is going to be ‘close enough’ and as close as I will ever get to throwing a leg over one of these beauties. Shame that Harley didn’t bring the Ala Verde over to North America.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 21, 2021, 05:18:46 PM
Moto Italia from California came through again for me, a complete rear hub, brake plate and axle for the 1961 Aermacchi 250, for a 17 inch rim, just needs some cleaning up

(https://i.postimg.cc/3rFDsDMB/CF5339-D7-F211-452-A-9-F02-D752953-CA281.jpg) (https://postimg.cc/K44zLj8k)

a half hour of vapour blasting and stripping and more blasting, ready for polishing and then lacing the new spokes to the new rim Moto Italia provided

(https://i.postimg.cc/tTCdg5N5/20-B2-DBCF-C206-4-DA2-BDE5-370-BA6-E1442-C.jpg) (https://postimg.cc/4KqHLpM7)

The threaded bearing retainer was a bugger to get out, lots of heat from the butane torch and using the right pin wrench helps, the nut had been bashed with a chisel in many spots before, I redrilled two holes 180 degrees apart for a snug fit to the pin wrench 4mm studs

(https://i.postimg.cc/zXDR8X81/318695-FA-48-F2-4972-8-C26-D7616-CFD4627.jpg) (https://postimg.cc/9zSfB2Dx)

pulled the blind bearings

(https://i.postimg.cc/wM5scR2v/8992-AA42-6285-4388-B738-0-DC4455-CDE6-B.jpg) (https://postimg.cc/8f55T5qQ)
Title: Re: Littel Green Wing - Aermacchi Ala Verde
Post by: Muzz on September 22, 2021, 04:23:53 AM
I am in awe.  What more can I say.

The way you casually fix insurmountable problems (to me anyway) never ceases to amaze me.
Title: Re: Littel Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 22, 2021, 10:31:00 AM
Thanks Muzz, having the right tool for the job makes difficult jobs so much easier, I never knew there were so many uses for a simple pin wrench, indispensable for opening up shock absorber reservoir caps too.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: riguzzi on September 24, 2021, 12:36:07 PM
I'm just putting my 68H back together before I start on my v50's. Nice little bikes!
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 24, 2021, 05:36:05 PM
I'm just putting my 68H back together before I start on my v50's. Nice little bikes!

 :gotpics: :gotpics:
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 28, 2021, 06:51:10 PM
A liitle bit of progress with the Aermacchi, I put a new pair of wheel bearings into the rear hub that Leslie Bull of Moto Italia provided,

(https://i.postimg.cc/pTDxFjqq/05-A396-D3-C411-40-E0-B0-A5-C2150-C9-C54-D9.jpg) (https://postimg.cc/47NrCYC9)

Polished up the aluminum hub, deglazed the brake shoes

(https://i.postimg.cc/QChDkMzs/3-D6-B75-C2-7-E4-A-4528-AAC5-BCFDA7-DFD1-A2.jpg) (https://postimg.cc/Q94vjjsn)

Moto Italia also provided a new Radelli 17" chrome rim and a set of new stainless steel spokes and nipples from Buchanans

(https://i.postimg.cc/J0xLTLwX/4-BA4-F469-83-D3-4701-883-D-057-E7-B9-D7002.jpg) (https://postimg.cc/V0Jp62ks)

rear wheel all laced up, next to true the wheel and then mount a new tire and tube

(https://i.postimg.cc/bNY8Zsb9/6-D906-E0-C-47-B3-479-B-8-A6-A-27-B04-C8748-A4.jpg) (https://postimg.cc/RqY28CgW)

I need to call Buchanans and find out if they can make a set of new stainless front wheel spokes from measurements I provide or if I need to send the Honda Black Bomber CB450 front hub and the 17" Radelli rim to them.

Anyone know where I could find a new rear sprocket for this 1961 Aermacchi rear wheel?
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 30, 2021, 05:57:23 PM
I found a Benelli front fender on Ebay that looked like it might fit, I think it will be ok, the top mount has a single tab rather than the double screw tab that wouldbe on the original

(https://i.postimg.cc/9McB8md1/92-BF28-C0-EB28-4061-83-E3-FA251-B98-E279.jpg) (https://postimg.cc/yJr9WzrS)

Got the rear tire on the new rim, 17 x 3.00, I think it looks ok

(https://i.postimg.cc/SKPkpLLv/4352383-B-959-C-403-C-8515-E78831-F0896-F.jpg) (https://postimg.cc/CZbWGqQG)

I have a couple Harley 250 Sprint rear fenders but none of them fit correctly or look right. I removed the mounting tab on the 62 ~ 66 rear fender I have to try and massage the location of the fender and mount but its not going to work, the 68 on rear fender alos is too big

(https://i.postimg.cc/YS0MVDFF/E1-B1-E57-F-4-EAF-47-A3-A4-C4-A0-C0864-C2876.jpg) (https://postimg.cc/G4WWTQq3)

I think I will look for a Sears 106 SS Gilera fender, my 106 SS rear fender looks like it will be a better fit, the Gilera also has a 17" rear wheel

I screwed up ordering a natching new 17" rim for the front wheel, I was planning on using a Honda CB450 Black Bomber 2 LS front hub but didn't check that it is a 40 spoke hub and I ordered a 36 spoke rim, I might look for the Aermacchi front hub for the 1961 17" wheel
Looks like 17" rims with 40 spoke holes are very hard to find

(https://i.postimg.cc/YS63zGWh/6-DECCCFC-050-D-4945-8-D2-E-09-EC3793-A9-A0.jpg) (https://postimg.cc/bGvkzvLh)

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on October 07, 2021, 06:29:24 PM
I took the big valenced rear fender I have to a motorcycle bone yard today in search of a smaller diameter fender that looked more like the slim Ala Verde fender. The bike wrecker in town is a disaster, two storeys of mostly 70'e Japanese parts stacked high on wood shelving with hardly any identifying marks and parts just piled on top of one another.

My search did go pretty quick, I found a rear fender, Japanese, probably early 70's by the signal light mount bracket that was bolted to the fender and it appears to be from a bike with a 17" rear wheel, much smaller than the Sprint rear fender. It is free of dents, appears to be stainless and was mine for $50

I think this will work with some fiddling, I need to weld up some holes, drill new holes, weld in some backing plates etc...

(https://i.postimg.cc/1z3KtzcZ/9447-BCF2-56-E2-4-AAB-A29-D-45634-F035-AFA.jpg) (https://postimg.cc/VJ2tZmV7)

I had a rear lamp holder and plate bracket that has the bottom 1/4 rusted off, it is of the style that came on the Ala Verde, I cut off the rusted bottom and foled over a lip, the upper bracket holes actually line up with existong hloes in the fender, perhaps some good Karma?

(https://i.postimg.cc/Hk22dMM2/FE245-E17-D5-CD-44-C1-8-BC1-088477-BF8-F8-E.jpg) (https://postimg.cc/qNNnGzjh)

There are many variations of rear fenders on Ala Verde motorcycles on Google, This is one example that sort of looks like the fender I found

(https://i.postimg.cc/fRdR4703/unnamed.jpg) (https://postimages.org/)

I need to fabricate a bracket for the bottom of the plate holder to bolt it to the fender. The seat cover is sitting over top of a smaller Aermacchi seat, I am waiting on a used seat frame for an Ala Verde to come from Italy.

I am pretty happy with how its coming together

(https://i.postimg.cc/Bv7B1GMP/8-B84-D67-E-635-D-46-C4-8411-1-A3-B399-A1-C54.jpg) (https://postimg.cc/2qvZPgpC)

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on October 09, 2021, 12:54:17 PM
It's looking really good, Jim.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Chuck in Indiana on November 12, 2021, 07:35:37 AM
Quote
Thanks Muzz, having the right tool for the job makes difficult jobs so much easier,

I've said many times that having the right tool is generally 2/3 of the job. Sometimes, you just have to make it..  :thumb:
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on November 24, 2021, 07:32:45 PM
I was still not happy with the rear fender I found, the Ala Verde has a rear fender with shallow skirts set into sheet metal folds of the main fender body, and it has to be suitable for a 17" rear wheel.

(https://i.postimg.cc/ncynL6YT/other-makes-all-models-S3761406-3.jpg) (https://postimages.org/)

I took a look at the rear fender on my Sears Gilera 106 SS, another Italian motorcycle with17" wheels and thought maybe it could be made to fit. I was lucky to find a very cheap Gilera 106 SS rear fender on Ebay, it was split at the rear and twisted buit salvageable. I welded up the original mount holes in the Gilera fender and removed a rear fender bracket from another later model Aermacchi Sprint fender and went to work with the hammer, dolly and welder.

The brackets fitted

(https://i.postimg.cc/dVqqRVt4/E6-E0-E12-F-BC89-409-F-842-D-892099-DB5-E56.jpg) (https://postimg.cc/bsBcp8nt)

I was also very fortunate to find an original Ala Verde seat frame (year unkown) on Italian Ebay, I blasted it clean and then I removed the rear seat bracket to position it over the center of the rear fender main support

(https://i.postimg.cc/HkwtPR1H/7650-F6-BE-814-F-495-A-B839-7744-EFA303-B4.jpg) (https://postimg.cc/v4m94PmS)

I need to remove the front seat brackets and reposition them as well to align with the Sprint frame seat support, should be an easy job

(https://i.postimg.cc/R0vTrdvt/24354760-F0-AD-4-BE3-82-FC-99-C105-ECCBF7.jpg) (https://postimg.cc/VJHtnjrs)

I found a reproduction Ala Verde hump back seat cover in Italy, it fits great, seat cover loosley fitted for alignment

(https://i.postimg.cc/CLf7bdvR/570-D3479-E92-F-45-BA-AF43-D7359-EDF0627.jpg) (https://postimg.cc/rKM5ky2T)

Ebay turned up a correct 1961 Sprint front fender that I will use (the blue fender I have on the bike is from a Benelli) and Moto Italia sent me a complete front hub and axle for the 17" front wheel,

The Honda Black Bomber front hub is now surplus, if anyone needs it let me know, willing to let it go for cheap with a pair of new shoes.

Getting closer to sourcing all the hard to find bits. I need to modify the front fork shrouds to expose the top of the fork tubes and fit the original type clip ons. I would alos like to find an emgine case side cover with "Aermacchi / Harley Davidson" cast into the alloy, this would be correct for the Ala Verde circa 1961, if anyone knows where I can find one please send me a pm.

(https://i.postimg.cc/nVWTsq18/A9972-B88-E1-DB-4-BD7-B9-D3-31157212452-A.jpg) (https://postimg.cc/5jw8TYGp)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on November 25, 2021, 04:59:59 PM
I took a closer look at the seat before rewelding the support brackets into position, the years of use had resulted in the hard spring steel cuting the mild steel frame,I  rewelded up the frame at the spring mount locations

(https://i.postimg.cc/mk4M7mGT/C699-A67-D-0-FDC-4-FAA-AC35-2-E32-A6020463.jpg) (https://postimg.cc/34LdTCRq)

Two of the horizontal springs were missing, there are four different lengths of springs and the two coil vertical main support springs are missing as well. I had a spare sprung seat that came with another project that is surplus so I removed the missing springs I needed from the spare

(https://i.postimg.cc/qMkyRDLL/E559-DC98-1597-4155-AEA7-43-AB5-F4-BCC46.jpg) (https://postimg.cc/kDpBYcL6)

All the springs fitted, and the front support brackets were removed from the seat frame by drilling out the spot welds, reshaping the brackets and then cutting down the width of the bike frame seat mount to fit the Ala Verde seat

(https://i.postimg.cc/wvLLtSZW/ECD0738-C-0-A22-4431-8-FA6-05-EE7840-D9-D1.jpg) (https://postimg.cc/gXcnQBYR)

I used four vice grips and a spirit level on the bike frame and a level on the seat top to level the seat brackets mounted on the bike prior to welding the whole seat back together

I can’t rotate the image but this is the final fixing of the seat, now to paint the frame and then permanently mount the new seat cover

(https://i.postimg.cc/Dzt1w2jJ/3604-A8-F4-ABB2-468-D-A5-BC-EC41-C1147469.jpg) (https://postimg.cc/XZkr2004)

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on November 25, 2021, 05:26:36 PM
Sure is looking good, Jim.   

I got a 66C a few days ago, to have as another canvas.  Don't think it will go as far towards original as yours is going, but you've got my wheels turning..  Thanks for all these great detail pics.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on November 25, 2021, 06:41:24 PM
Thanks Clint! Glad to hear you got yourself a Sprint, parts availability is pretty good and should you choose to go with the Ala Verde look I think Leslie at Moto Italia has one more Ala Verde tank available.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on November 25, 2021, 07:45:12 PM
Mine is pretty not pretty, Jim, but the engine is complete with no fin damage. 

Right now it's likely going to be the platform for custom bodywork when the time comes, maybe something along the lines of a Linto 500.  Don't know that it would be feasible for a hack like me to marry a pair of engines together like Millyard (sp?) does to make it really authentic.   Just having a somewhat fitting partner to my Tonti-inspired Corsa Record will be enough for me.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on November 26, 2021, 05:23:20 PM

Right now it's likely going to be the platform for custom bodywork when the time comes, maybe something along the lines of a Linto 500.  Don't know that it would be feasible for a hack like me to marry a pair of engines together like Millyard (sp?) does to make it really authentic.   Just having a somewhat fitting partner to my Tonti-inspired Corsa Record will be enough for me.


A Linto replica would be very special!

I powder coated the seat frame today, my shop oven is just big enough to take the frame, black powder about to be cured

(https://i.postimg.cc/XvgTKpjr/549-BAECF-EDC8-429-A-BC7-D-A1502968-AAC5.jpg) (https://postimg.cc/kVB1qMtC)

I fitted the seat, I had to remove the cover and trim down the center upper spring bar and move the outer springs in about 8mm to get a proper fit, it is not perfect, I don't think the frame was actually for an Ala Verde but its close enough

(https://i.postimg.cc/wvwYz3ZC/6-DAE7-BFC-AA9-A-43-C2-93-E3-FADA19-D1-F60-B.jpg) (https://postimg.cc/0MKBd58n)

Upon remounting the seat to the chassis I found the rear hump is too tight to the rear fender, I extended the rear center mount bolt, fitted a spacer and then redrilled the seat side lugs to the fender bracket, a couple more holes will need to be welded up in the fender.

(https://i.postimg.cc/ZYfJtDhW/ECD69-DBE-2932-4491-B959-B2-E8118600-AE.jpg) (https://postimg.cc/Hj7qbznm)

I got a 1961 Sprint front hub from Moto Italia, the hub outer surface had some deep nicks and corrosion

(https://i.postimg.cc/j2Dmrczf/316-BC1-EA-09-F5-452-B-824-A-59-A878-A4-FA29.jpg) (https://postimg.cc/CnVmGjrM)

I mounted the hub in my lathe and starting with 100 grit dry I spun the hub and used a foam rubber backer with the sandpaper to sand out the nicks, it took about a half hour on the lathe working up to 220, 400 and then 1000 grit wet

(https://i.postimg.cc/FRy8Fzqr/1-E574-B8-D-2-BD2-45-D3-8-C9-D-5-A5324-AA3-F9-A.jpg) (https://postimg.cc/njL00Fpg)

I finished off with the bench polisher

(https://i.postimg.cc/9MmHsy8P/8-E86-AF93-634-C-43-B4-8049-3-D401019-C2-F8.jpg) (https://postimg.cc/VSVhC0c5)

Reassembled the brake plate and test fitted the hub and installed the 1961 Sprint front fender

(https://i.postimg.cc/02FxrMjx/D69-BF359-B911-4967-A5-E5-38-CFAFB957-C5.jpg) (https://postimg.cc/zVC4cfTP)

It is starting to look a little more like an Ala Verde

(https://i.postimg.cc/02bP8d8c/A91-A6584-6-E2-E-4191-B5-C7-5-C896503-EA0-B.jpg) (https://postimg.cc/dLPz6CZy)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on November 26, 2021, 06:04:54 PM
Yup- very cool. 
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on December 19, 2021, 05:54:47 PM
A little progress towards getting the Aermacchi to rest on two wheels, it will need a stand, the original stand bracket was partialy cut off the frame I started with, Harley Davidson offerd the side stand bracket as a separate option to weld to the frame, found this one on Ebay

(https://i.postimg.cc/26Z90gMk/EE5465-A6-5-D4-C-4-EF0-AF2-F-5-BD2-D3-A16-C15.jpg) (https://postimg.cc/phPBTcP4)

Zipped the remainder of the old stand off and welded n the new bracket

(https://i.postimg.cc/jqfBcJYH/CA480-EC2-DC69-4580-A607-3314-F6-D1-D101.jpg) (https://postimg.cc/dDqWt313)

I removed the mock-up motor to weld the bracket and swapped in the 250cc Sprint engine I had rebuilt a couple years ago

(https://i.postimg.cc/v86wKNf6/EA27-FC37-85-C6-4520-9-A05-59-A4-FAF9-B68-A.jpg) (https://postimg.cc/PNh7pK6t)

(https://i.postimg.cc/9Fd5mwxm/4-CDC1-CE6-F15-E-4420-88-C9-FFFBD323-CB7-E.jpg) (https://postimg.cc/yk8rnx4t)

I fitted the repro header and muffler and the heel toe shifter I found on Italan Ebay

(https://i.postimg.cc/wBbnfXBV/5186225-C-FB3-D-4570-9271-92336-C6342-E1.jpg) (https://postimg.cc/3ymLWDm4)

side stand and brake linkage cleaned up

(https://i.postimg.cc/HkYKTZcz/A4-EB60-D7-FD12-40-F8-8196-496-A3-FCB9097.jpg) (https://postimg.cc/ykGnPTT3)

I dropped the front wheel I laced up on Saturday, getting a new tire and tube installed and then the little Green QWing can be rolled into a corner

(https://i.postimg.cc/QMMRJ4jC/DD53-DE5-A-07-E2-4-A8-F-8-EFB-62831560201-C.jpg) (https://postimg.cc/dhzHq9kc)


Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on December 24, 2021, 03:09:43 PM
On two wheels (and a side stand), the little Green Wing moves to the backburner now to make way for other projects

(https://i.postimg.cc/tCWP5zbk/2890-EFE4-12-BD-4824-BB45-21-D23-D7-D20-E4.jpg) (https://postimg.cc/w7x7xL7R)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on December 25, 2021, 09:55:34 AM
Sure does look good, Jim.   These pics will pester me about what could be done with my rusty old pile....
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on December 25, 2021, 12:35:07 PM
Merry Christmas Clint!

And thanks for the kind words.

 I will keep doing small things and adding parts to the Aermacchi to the point of getting it running then disassemble for cosmetic work down the road. I want to finish the Airone before I get into the full deal on the Aermacchi or Benelli, and that oil consumption issue with my Ducati 860 has me occupied right now.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on December 25, 2021, 03:02:34 PM
Merry Christmas and Happy New Year, Jim.    It's lots easier to be happy with my old piles when I can have them in sight, doing a little at a time until the real time comes.  We had a similar inexplicable oil leakage issue that turned out to be the mentioned small crack that only leaked after engine was hot and under pressure.  But in my well-developed state of crs, right now I can't remember what bike/engine it was...

No matter, I would have a hard time focusing upon either the Aermacchi or the Benelli with that Airone around.  They're just not in the same league.  That's such a nice looking old single- it's coming out great.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Bob Wegman on April 01, 2022, 12:30:15 PM
I am a big fan of the Aermacchi sprints.  Don't have one at present but did have a 1972 ERS350 sprint new.  Rode it at local dirt track races and on the ice. Sold it pre internet days, because I was worried I wouldn't be able to find parts if it broke, and have regretted that ever since. 
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 01, 2022, 08:25:22 PM
I am a big fan of the Aermacchi sprints.  Don't have one at present but did have a 1972 ERS350 sprint new.  Rode it at local dirt track races and on the ice. Sold it pre internet days, because I was worried I wouldn't be able to find parts if it broke, and have regretted that ever since.

I have not made any progress on the Aermacchi, busy finishing other projects but I will get back on to it.

I have a ERS frame - serial number *7B10021HO*, I have the HD/Aermacchi guide book that list serial numbers, this is one of some 400 +/- of these that were produced,I think it is a 72'  it has the swing arm and the rear wheel but nothing else.

(https://i.postimg.cc/B6cCjCkV/IMG-0095.jpg) (https://postimg.cc/ygxR50Vm)

(https://i.postimg.cc/8k7RQNPY/IMG-0096.jpg) (https://postimg.cc/rzL0564G)

I can probably get the tank and rear fender from the original owner if someone wanst to build one of these flat tarcker / MX bikes

If anyone is interested in it send me a PM, shipping could be expensive from Canada but I won't be asking too much for it, it would be nice if someone would assemble a racer out of it.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Scout63 on April 01, 2022, 09:59:35 PM
I love this thread and am glad you bumped it Jim. You operate at a whole different level.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Petrus Rocks on April 02, 2022, 10:57:14 AM
Great project Canuck!  Gives me something to shoot for with my projects.  The Aermacchis are a real neat bike!
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 02, 2022, 04:43:13 PM
Thanks Fellas!  The Aermacchi is taking a back seat to the Benelli / Motobi 200 Sprite build, I am getting close to sourcing the last bits I need for the engine to go back together. Started on my 1975 Moto Morini 3-1/2 this week, I bought it years ago knowing the engine needed rebuilding and I finally got tired of looking at the poor Morini so I finally am getting into it.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 26, 2022, 02:43:04 PM
Been a long time since the Aermacchi got any attention. I went to the Imola swap meet in Italy this summer and found two engine side covers I have been after to create a tribute 'Ala Verde' Aermacchi / Harley Davidson. Both need some work, one has been poorly welded, the other has a chunk missing.

(https://i.postimg.cc/kX7n4mkW/IMG-E4188.jpg) (https://postimg.cc/BtwWYdZv)

cleaned up for welding

(https://i.postimg.cc/cJXM80J2/IMG-E4634-1.jpg) (https://postimg.cc/t1nVK0WN)

I got inspiration from an Ala Azzura (Blue Wing) that was on display at the Italian Transportation Museum, this was the first model imported to North America that was sold as the Wisconsin, the Ala Verde (Green Wing) has the longer tank, exposed shock springs, slender rear fender, clip on bars

(https://i.postimg.cc/5yXYzYf0/0367-FA53-183-B-4-AD0-ABEB-2-B288145-AAAF.jpg) (https://postimg.cc/BPGn9vL9)

(https://i.postimg.cc/DwkJWwHv/7-B569812-305-F-4533-957-B-42-B4-C1-E5-C29-C.jpg) (https://postimg.cc/3d1JVY3V)

(https://i.postimg.cc/BbR8BSvC/823-E4981-AAE5-4098-8852-58332-E48-CDCC.jpg) (https://postimg.cc/YLfqpwY4)

(https://i.postimg.cc/P5YDKwYv/C13848-C8-5-F5-E-4117-A6-C3-5-E1-FA2-F3995-A.jpg) (https://postimg.cc/DSfmwmC7)

(https://i.postimg.cc/vB3ffw9P/E2-B5980-C-152-D-4496-9-CC7-9-A0842-C2161-D.jpg) (https://postimg.cc/BLPjfymD)

(https://i.postimg.cc/WzyZYm5g/A32651-A9-FF9-B-47-D9-8-AF2-36-D0-AA47-E3-E8.jpg) (https://postimg.cc/30gWdG5x)

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Dave Swanson on September 29, 2022, 08:21:33 AM
Wonderful bike and work.

If you haven't spotted this auction there are some fabulous bikes including this Ala Verde.

https://astebolaffi.it/en/lot/151/23/detail
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on September 29, 2022, 12:00:16 PM
Wonderful bike and work.

If you haven't spotted this auction there are some fabulous bikes including this Ala Verde.

https://astebolaffi.it/en/lot/151/23/detail

Thanks for the link Dave, the web site has some great pictures that will be a great resource for my project!

I took some pictures of a Ala d'Oro (Gold Wing) factory over the counter race bikes that were on sale at the Imola swap meet this September, there were about a half dozen of these Aermacchi 250cc races on offer, I didn't ask for prices. One guy had three lovely ones for sale, all fully restored. I didn't see any Ala Verde's for sale.

(https://i.postimg.cc/NFFFWRYz/EFA3-E87-B-4-B5-F-4-F1-F-913-C-DAEFAB569961.jpg) (https://postimg.cc/hQFKmzXL)

(https://i.postimg.cc/NF3JW7ms/508-A0-ADA-7847-4-BAD-94-D4-5-A38804-E59-FE.jpg) (https://postimg.cc/9wBY99LK)

This group of rare Italian eye candy was on offer, the Parilla racer is gorgeous, as are the rest of them! Instant Giro bike collection.

(https://i.postimg.cc/gk3Ld2dN/55137-EF4-2-F29-4-CE9-8890-E318-EAA9-FDBF.jpg) (https://postimg.cc/w7TjQH1m)

I think I need to organize an Imola 2023 trip, rent a van and figure out a cost effective way to get some fabulous projects back home.

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on October 06, 2022, 04:41:22 PM
My friend George finished welding up one of the Aermacchi engine covers I got at the Imola swap meet in Italy last month, some time on the mill with a boring bar to cut the points recess circular, and a lot of hand sanding and its pretty darn good IMHO

(https://i.postimg.cc/85c6F0HJ/IMG-4698.jpg) (https://postimg.cc/wyKvZFng)

A wee bit of pitting but thy were not perfect leaving the factory

(https://i.postimg.cc/prn5C53P/IMG-4699.jpg) (https://postimg.cc/BP4vQbqz)

this cover is the top one in the picture prior top welding and sanding, one more to go

(https://i.postimg.cc/cJXM80J2/IMG-E4634-1.jpg) (https://postimg.cc/t1nVK0WN)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on October 11, 2022, 06:58:32 PM
Looks really nice, Jim.  Glad you were able to find those covers while you were there.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on October 12, 2022, 01:02:10 PM
Looks really nice, Jim.  Glad you were able to find those covers while you were there.

Thanks Clint, I tried gas welding on an old wasted side cover I have, it was not a success, couldn't keep the weld clean and I was blowing through as well.

I watched some Youtube videos and ordered some new aluminum flux and some thinner filler rods and I need to back of my oxy and acet pressure to 4 ~ 5 psi.
A friend told me to try welding with propane, he says it works for him.

What gases do you use for your aluminum welding?
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on October 12, 2022, 07:35:57 PM
Thanks Clint, I tried gas welding on an old wasted side cover I have, it was not a success, couldn't keep the weld clean and I was blowing through as well.

I watched some Youtube videos and ordered some new aluminum flux and some thinner filler rods and I need to back of my oxy and acet pressure to 4 ~ 5 psi.
A friend told me to try welding with propane, he says it works for him.

What gases do you use for your aluminum welding?

I have both an oxy/act rig and an oxy/hydrogen rig.  The oxy/hyd is dedicated aluminum welding and I’m still learning- invisible flame, extremely low pressure like 2 psi.  But it’s much cooler so vastly easier to manage than hotter oxy/act.   Whether oxy/act or oxy/hyd, you will find significant benefit from using two stage regulators in excellent condition- especially when welding thin crs or alloy sheet.  Otherwise,  your flame will not remain stable and you’ll have lots more difficulty producing good work.  There’s a shop in Phoenix AZ who can rebuild regulators specifically for low pressure use like oxy/hyd.  He recommends Victor VTS-250 regulators, the only ones for which rebuild parts are still available.  He has rebuilt all my gas welding regulators.

But for something like that side over, I would TIG it.  I wouldn’t even consider gas welding it.  Much less chance of blowing holes because a much more finite area is heated/penetrated, so the whole piece doesn’t need to be on the verge of collapsing like it would be with gas welding.  Clean it out properly, make a few passes to build as needed and finish it.  I use 100% argon with my TIG. 

FWIW, my coachbuilding friend (also named Jim) regularly makes unobtainable parts by fabricating & TIG or MIG which are then finished with files & grinders (and even beadblast/sandblast sometimes for final surface) to the point that the part looks like a casting.  You should see the firewall braces he made for a Bugatti he is building- they look fantastic.  I did some of that already on my Corsa Record for the headlight ears prototype and will probably do more making the missing hand levers for these Menani clip-ons.  In fact, just got a MIG welder from Jim to add to the shop.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on October 12, 2022, 08:42:22 PM
Thanks Clint!  Excellent information. My ESAB welder can only TIG carbon and stainless steel. I have debated upgrading to a full AC / DC welder that could TIG aluminum as well but that’s going to cost me at least $2K more if I can sell my MIG / TIG / stick unit. I am going to spend an afternoon with my friend George next week getting some hands on experience TIG welding aluminum.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on October 12, 2022, 09:07:41 PM
If you have room for a bigger/older machine, there’s good deals on AC/DC TIG welders now that people keep switching to the smaller inverter welders.  I’ve got a Miller Synchrowave 250 that cost $1K with everything except the tank and am now seeing more in the same price range lately.  great machine- it will weld anything I need.  Some of the older TIG machines are even cheaper.  The smaller Synchrowave 180 units have fatal failure issues with non-serviceable diode boards, so need to be avoided.  I prefer the analog switches & dials over digital & touch pads, even if I don’t know where they need to be set….  Don’t know much about new machines.

One local welding supply shop has a service dept.  The manager/technician regularly has new take-off regular equipment water-cooled TIG torches that the pros switch out for their preferred torch when they buy a new machine.  Nothing wrong with them.  It’s just not what they're used to using so they don’t want them.  Says it’s pretty common and items are disposed of for a good price.  Might be worth checking if you have a similar supply shop with service dept to see what might be available to save $$.   
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on October 12, 2022, 09:51:30 PM
Thanks again Clint, I will check with a couple welding supply shops here.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on November 24, 2022, 05:20:20 PM
The ‘second’ engine side cover I brought back from Italy this summer had been welded up very poorly. My friend George the professional welder tried TIG welding up the holes but the filler material used was very contaminated and kept popping with each pass. After two attempts to weld the case George decided it would be best to cut out all of the old weld and make a new piece to weld in.
George used a plasma cutter to remove a large section of the case. A new piece of 4.5 mm aluminum was formed in a hydraulic press to create the concave firm and then after a lot of forming with a hammer and anvil the new piece was tacked in

(https://i.postimg.cc/kGnnCnMG/ED01AC30-064A-4826-A5C8-B71941601C35.jpg) (https://postimg.cc/hz5FbRdR)

Welded up from both sides

(https://i.postimg.cc/50GVQ65s/2BE0F6C3-303A-4805-A2B7-15228DECDEF3.jpg) (https://postimg.cc/gXv5fcTh)

(https://i.postimg.cc/pdsxx0mb/C11339F0-43B4-408C-AF99-7BEC6A10DBCF.jpg) (https://postimg.cc/R3J2LL1X)

Plenty of work with a die grinder, file and sanding and it’s pretty damn good

(https://i.postimg.cc/mDh4rQ9c/B260945F-0F17-44A6-B350-CF6282FC2E4F.jpg) (https://postimg.cc/JDwv6HPm)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on November 25, 2022, 08:30:02 AM
Very cool!  Glad to see that one was also successfully repaired. 

Not sure if it was a pic here here on WG or elsewhere, but didn’t they make three versions of lettering on these covers?   Thought I saw pic of one that only said Aermacchi (maybe from one of the various Italian Bike museum pics) plus yours that say either Aermacchi Harley Davidson or just Harley Davidson.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on November 25, 2022, 10:31:43 AM
Very cool!  Glad to see that one was also successfully repaired. 

Not sure if it was a pic here here on WG or elsewhere, but didn’t they make three versions of lettering on these covers?   Thought I saw pic of one that only said Aermacchi (maybe from one of the various Italian Bike museum pics) plus yours that say either Aermacchi Harley Davidson or just Harley Davidson.

You’re right Clint, at least four versions of the Aermacchi side covers, some had no text at all, just the raised ribs.
This version with just Aermacchi

(https://i.postimg.cc/vBDkQbKz/93-E4366-F-3-DB7-409-A-94-A2-C617-B4-C616-CD.jpg) (https://postimg.cc/k63fs3q6)

Then the dual Harley Davidson / Aermacchi text and the typical North American version with just Harley Davidson.

I brought my welding shield to my friend George’s place to get up close and watch his TIG skills, it was so valuable to observe his moving of the puddle and when he added filler rod. I got to practice a bit laying a bead and with George’s help my feeble aluminum TIG abilities improved. I am still on the lookout for a used AC/DC TIG machine to get practicing on my own.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on November 25, 2022, 04:04:13 PM
Seemed like a good time to mount the 'new' side cover onto the right hand side

(https://i.postimg.cc/YCFcV5QC/2-AB5-AEAE-288-F-40-B3-8-FDD-A949-E26621-C1.jpg) (https://postimg.cc/k27hRhj0)

I was also lucky enough to find this European market left hand side inspection plate

(https://i.postimg.cc/KvwS0GkW/874920-B6-4-EE5-4-D0-C-A52-C-34-F8-C0-C5-FD3-F.jpg) (https://postimg.cc/zVCcB1kw)

I hope to make some serious progress on the Macchi this winter.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Frenchfrog on November 26, 2022, 04:39:37 AM
Stunning work !
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on November 27, 2022, 08:21:02 AM
It’s looking great, Jim.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on February 20, 2023, 11:13:31 PM
This winter another Aermacchi 250 motor came my way, this is a 68 model, the 67 and 68 250 four speeds went with a short stroke and bigger bore, the pre 67' 250 had a 67mm bore where as the 67' to 68' have a 72mm bore. Period test reports claimed more power out of the redesign and this reporting was repeated in the Ala D'Oro race bikes that got the short stroke motor in the early 60's.

(https://i.postimg.cc/HsnGFXJ1/91-EFCF0-E-5866-4444-BA08-819-DFBE135-F9.jpg) (https://postimg.cc/Lhc01qBx)

Every 67 ~ 68 I have seen had the 'Cactus' head and rocker cover on them but this one is different, the piston / cylinder is a 72mm but the head has the 61 ~ 66 and 73 and 74 knuckle style head. The cylinder barrel protrusion fits as it should snuggly into the cylinder head recess and it was a complete motor. The rod feels good but the case bearings need replacement, an oversize piston is needed and the exhaust guide is worn but other than that it looks good. Engine cases are stamped 68 SS so its a bit of a mystery.
I think I will rebuild this motor and use it my Ala Verde tribute, it will need all the power it can get!

Though similar to the Benelli 'egg' motors (125 / 200 / 250cc) the Aermacchi crank is supported by one double row ball race and one single row ball race bearing on the opposite side. The Benelli singles have a double row ball race and stacked up, a single row ball race on each side of the crank, belts and suspenders!

The Aermacchi motor started life as the 175 Chimera before evolving into the 250 series motors. Period race reports of the early Aermacchi race 250's; the initial Ala D'Oro 250, praised their competitiveness but complained about their fragile engines. Aermacchi redesigned the motor to a short stroke 250 in the early 60's and supposedly the reliability improved.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on February 22, 2023, 07:20:13 PM
This past Saturday I stripped down an Aermacchi 250 motor and ordered all new case bearings from 123 Bearings in France, amazingly the order arrived this morning including the shaft seals.
Cases heated to 300F for a good half hour, bearings cooled in the freezer, bearings drop in with a satisfying clink.

(https://i.postimg.cc/ZRL3KKQP/6-A191-E72-78-D6-4-AA2-B83-C-044987-FDF931.jpg) (https://postimg.cc/vgcD0MbD)

(https://i.postimg.cc/4NytsGQt/5-F1-C9-FB0-510-B-446-E-9468-E4-A1-B9-F78-BEF.jpg) (https://postimg.cc/hfFh1HwP)

The head has been heated as well and the worn valve guides drifted out, new guides on order.

I noticed three of the rocker cover recessed 6mm holes are striipped. Not much extra metal around the holes for an insert so I have to be precise drilling for the inserts. I made a steel plate jig that I can bolt the head to at a sixty degree angle to the milling machine table, some shimming to get the rocker cover face dead level in all directions then drilled and taped for the steel insert.

(https://i.postimg.cc/NMRD8czL/35981633-F554-4045-8-CB0-A8-A70482-C825.jpg) (https://postimg.cc/LY6jRrRM)

I set the tap in the mill collet and rotated the quilt by hand to tap the inserts M10 x 1.25 inserts.

(https://i.postimg.cc/QCsb0y2m/5435-FE5-B-B238-4-E43-A6-F9-BF83-CE285-B7-A.jpg) (https://postimg.cc/k61K5fXR)

Thread the insert down and stake the setting tabs

After locking the insert I flat file the top of the insert flat with the rocker cover gasket face

Three inserts installed and the head is good to go for new guides and a valve grind

(https://i.postimg.cc/Z5gx1nkC/C7ED9DFC-FE03-48F9-8093-CB61998B250B.jpg) (https://postimg.cc/WdGZZ21v)

I found a NOS con rod, pin and big end bearing, the bottom end should be as good as new.





Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on February 22, 2023, 07:59:55 PM
As always, I’m really enjoying seeing your progress..  Thanks for the pics and update, Jim.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on February 22, 2023, 08:29:55 PM
Thanks Clint! I am enjoying learning about these Aermacchi singles from the 60’s and comparing them to the Benelli Egg motors I have been building. Each have their unique details, I like the rugged clutch design of these wet clutch Aermacchi engines with the one huge compression spring, a very clean design in my opinion. The cases are also very thick and have plenty of web reinforcement, the Benelli cases don’t feel as solid. The Aermacchi cranks have full circle flywheels, large diameter and heavy, much larger than the 250 Benelli single crank flywheels. One thing the Aermacchi engineers got right is the cam shaft with its bearing carrier and the tappets can be removed without splitting the cases and the kick start ratchet gear and spring are carried in the outer side cover, brilliant!
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 21, 2023, 06:55:11 PM
The power sport machine shop I use called to tell me the rebuilt crankshaft with new connecting rod, pin and big end bearing was ready and the bored out cylinder were done.

(https://i.postimg.cc/G3QH6pCf/0-B3-BEB42-2-A15-4-B8-F-A754-14-C9-F6-C30-F3-D.jpg) (https://postimg.cc/JtsrkMt3)

Sonny’s Aermacchi had the NOS con rod kit and Pooles Cycle in Hamilton, Ontario had the 1st over piston kit.
I followed a YouTube series Paul Brodie has run on building an Aermacchi race bike and used his method to shim the transmission shafts, end float shimmed to .004”.

(https://i.postimg.cc/sXJgFTtW/51-B35-A4-F-F327-4188-AF04-226-AB553-CBE2.jpg) (https://postimg.cc/1nfQwrRR)

Waiting on the machine shop to finish installing and reaming the new valve guides and cutting the valve seats.

All case ball bearings and shaft seals from 123 Bearing.

I found a contact in a Italy that may have a center stand and the correct upper triple clamp and fork shrouds for the Ala Verde clip-on handle bars, fingers crossed as this would complete my parts search to build an accurate Ala Verde replica.

(https://i.postimg.cc/HxmkPqPH/6887-E6-DC-B603-410-D-B1-E4-8-E2211-B4-C576.jpg) (https://postimg.cc/R3PmWDBb)

Another Italian contact sent me a picture of his fathers Aermacchi Ala Verde bought new from the factory in 1961 and still on the family. Beautiful machine in excellent condition.

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on March 22, 2023, 07:21:23 PM
Good luck with the short fork shrouds and smooth triple tree.  I know sourcing those racy bits can be really tough.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 22, 2023, 10:55:20 PM
Good luck with the short fork shrouds and smooth triple tree.  I know sourcing those racy bits can be really tough.
.

Hard to fine indeed! If my current lead falls short I will modify the fork shrouds I have and weld up another upper triple clamp and machine it smooth. I take my inspiration from your Corsa build, if you can’t find it make it!

Ps I might have another Sprite thanks to your tip!
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on March 23, 2023, 06:11:13 AM
I looked for a decade trying to find a short set of fork shrouds for my little Ducati Sport 80 to eliminate the upright bars.  That was mostly pre-internet and I never found any.  Between the difference in cone/taper and actual headlight ears vs regular Falcon & Cadet parts, making a pair were a major impetus in working towards Metalshaping work. The Corsa Record gives me a chance to still make parts in the same theme and maybe show others that it can be done by normal folks.  I’m anxious to get back to work on it.

Hoping the new lead works out for you.  Eggs usually come in a dozen, right?  You keep getting closer…
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 23, 2023, 07:59:15 PM
Thanks Clint!
I did score a center stand out of Italy today and plenty of pictures of an all original 1961 Ala Verde to study.

(https://i.postimg.cc/Hx5ZTdVY/21-D9-C46-B-DF89-431-D-BD6-F-4349-AF1-BB654.jpg) (https://postimg.cc/HcY42GwR)

(https://i.postimg.cc/nrG3Q24N/E17-C72-C2-3-B9-C-49-A5-880-B-5-F3-A5-E98-F3-EE.jpg) (https://postimg.cc/PvNWgmFM)

I have found very similar clip-ons and I think I can modify the fork ears I have by cutting them down and on my lathe making new steel top caps with an opening for the 30mm fork tubes and weld the new closure caps to the sheet metal shrouds.
Fir the triple clamp I will weld up a spare top cap and finish it smooth, it won’t be exact but close enough for me.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on March 23, 2023, 08:12:52 PM
Have you seen these repro clip-ons available that are very close, if not the same.  Look here if you haven’t seen this site, down towards the bottom of the handlebar listings-  https://www.motocicliveloci.it/inglese/catalogue/manubri_uk.htm (https://www.motocicliveloci.it/inglese/catalogue/manubri_uk.htm)

How are the headlight ears- regular vs clip-on shrouds?  Some for those cut down shrouds are very upswept vs the straight ones found on bikes with regular bars. 
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 23, 2023, 08:40:52 PM
I bought a pair of nice clip-ons with the lever perches welded to the bars and complete with levers. They are shown on Facebook. The Aermacchi parts for sale page. They are advertised as being for an Ala dOro (Gold Wing) but I think they are very close to what came on an Ala Verde.

The Ala Verde fork shrouds are just like the 1st year Harley Sprint fork shrouds I have but they are shorter above the welded on fork ears. This a picture of my project with the typical bars mounted on top of the triple clamp.

(https://i.postimg.cc/VN3gbSmM/IMG_5531.jpg) (https://postimg.cc/Nykm3jyf)

This is what I am trying to copy, smooth top triple clamp, clip-ons mounted to 39mm fork tubes and steel shrouds with welded on headlight ears.

(https://i.postimg.cc/Hx5ZTdVY/21D9C46B-DF89-431D-BD6F-4349AF1BB654.jpg) (https://postimg.cc/HcY42GwR).

Another idea I have is to just slide the fork shrouds I have downward by notching out the cut out for the lower triple, then weld up the extended lower triple slot and cut off the bottom of the fork shroud, I think this may be the least amount of work and not impact the geometry of the shroud. Just some careful steel sheet welding for the modified slot at the lower triple and some grinding.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on March 23, 2023, 09:30:50 PM
Is there a difference in diameter between the top of fork shroud and where you may cut them?   There is often enough difference that a shroud or headlight ear that is only shortened from the top has a very noticeable if not dysfunctional mismatch where it meets the clip-on handlebar.  With the taper that’s often present  on both crs or cast alloy parts, it takes more creativity to make it look good. 

At least those are crs, so hopefully the Aermacchi parts are more forgiving to modify.  I’ve learned that comparable parts on other marques aren’t.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 24, 2023, 09:36:43 AM
Good points Clint, when I get the clip I-ons I bought I will start taking measurements and come up with a plan. It’s a good challenge, plenty to learn about sheet metal I think.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on March 24, 2023, 12:09:45 PM
You’ve got me wanting to do the same thing with this sprint lump I have, Jim.  So I’ll be watching. 

Dropping the shrouds and trimming the bottoms sounds like the better plan, especially if the headlight ears are removed & relocated towards the top.  Even if the ears need some modification near where they are spot welded(?) to the shrouds, it would probably be the quickest and least difficult path. 
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 24, 2023, 01:41:28 PM
I asked the fellow I bought the center stand from in Italy to post some detailed pictures of his father's Ala Verde fork shrouds and clip-ons, some good pictures should help.

I got the bottom end assembled today, there are so many little differences over the model years to these 250/350 motors that a factory Service manual is essential. HD / Aermacchi changed the cranks and bore in 1967 - 1968, then in 69 they went to the 350, There are differences in clutch, gear shims etc for various series of these, a bit confusing but I think I got the clutch basket, crank pinion and cam gears properly installed and end float shimmed to tolerance. I bought a of shims recently for the Benelli motors, they sure came in hand on the Aermacchi as well. What is it with Italian motors and shims?

(https://i.postimg.cc/05Z1pzxM/IMG-5589.jpg) (https://postimg.cc/xqkZQTXn)

(https://i.postimg.cc/bwVQbHVC/IMG-5598.jpg) (https://postimg.cc/XrFG6Fbd)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 24, 2023, 09:28:29 PM
The tale of two different fork shrouds, the 1961 HD / Aermacchi Wisconsin type with 17” front wheel and typical handlebars clamped onto the top of the upper triple.

(https://i.postimg.cc/cH7kGsN8/12D49768-D879-4873-8C33-D3672CD9D548.jpg) (https://postimg.cc/S2sfWbRy)

Picture of an original 1961 Ala Verde from an Italian owner sent to me this evening.

(https://i.postimg.cc/3RwYdbJN/4F189A41-9815-4BCB-BD2E-70A1549B22D5.jpg) (https://postimg.cc/KKCdWfTh)

The signal lights have been added by the owner and the original flat clip-ons replaced with upswept clip-ons

(https://i.postimg.cc/mkz4Sz9G/25D1A38A-3BE7-405A-9403-FABF17A3FAD5.jpg) (https://postimg.cc/m1sKLrVd)

I am looking forward to figuring this out.

I think the best plan is to drop the fork shrouds lower on my bike by increasing the slot in the fork shroud at the lower triple clamp and then welding in a closure piece of sheet metal to return the slot to a stick look, then trim down the bottom of the shroud. I could also trim down the top of the shroud and weld in a new steel cap I can make on my lathe with an I.D. Of 30mm to let the fork tube to run through.

Thank god fir motorcycle enthusiasts all over the world!

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on March 30, 2023, 10:52:15 PM
This week I tried my hand at some sheet metal work, the rear fender I am using is off a Sears Gilera 106, it is the closet thing I could find to match the Aermacchi Ala Verde rear fender, like the Gilera the Aermacchi has a 17" rear wheel so the radius and clearance to the rear tire works with this fender. The problem with the fender I have is it is pretty beat up, the rear of the fender is cracked and a lot of rust at the edge and the sides are flimsy and cracked as well.

I decided to cut out the side panels and replace them with solid metal cut from 22 gauge sheet stock. A card paper pattern

(https://i.postimg.cc/GhpgJ9Zc/F499-D2-EA-0222-433-B-93-C1-FBCC5266-FB65.jpg) (https://postimg.cc/3WPZ3r86)

Cut out the old steel

(https://i.postimg.cc/nV2wDqSR/E485911-C-7443-4-EB6-B306-6-AEAF37-A6201.jpg) (https://postimg.cc/6T70s4Xn)

I folded the top edge of the patch panel to rest on the lock seam of the main fender

(https://i.postimg.cc/VL7T3Xjr/0864-F6-EA-F341-468-E-A6-FA-3-D4-D31-BD00-D6.jpg) (https://postimg.cc/PPw2DpVT)

Then welded in the patch

(https://i.postimg.cc/hP46y27R/199-D1938-CFF1-44-FB-8-EFB-A8-E0-A1-F37-D67.jpg) (https://postimg.cc/nM53MYk3)

I bought a couple tool steel rods, 1/8' diameter and welded these to the inside of the patch to make a beaded lip

(https://i.postimg.cc/bJQWMMTp/085-EC6-DC-5570-4-B6-D-A014-F7-FC2-D9-C8-A79.jpg) (https://postimg.cc/CBxcncXQ)

I blended the rod to the original folded lip

(https://i.postimg.cc/0jCg63Mc/06-BA29-E4-83-F9-44-DB-9-C4-A-107-C9110-A22-A.jpg) (https://postimg.cc/q6gDS1G3)

I had an Aermacchi rear fender I was not using and cut out the rear of it to patch into this Gilera fender

(https://i.postimg.cc/FzpqFL86/6-D3-A6-FF2-ADB5-4-E46-BFDA-2-B37-DA4-BA8-E2.jpg) (https://postimg.cc/MfctdvW0)

(https://i.postimg.cc/ydq2LB0L/D081-DFFF-9604-47-CC-BCA5-D2-F893234-AAB.jpg) (https://postimg.cc/mcwdrvX9)

welded the patch from both sides and ground down the welds

(https://i.postimg.cc/jjnG6CnW/4-E6-D9247-FA84-4-A76-B081-4524432-AABF1.jpg) (https://postimg.cc/d7vHwsBv)

I think it all turned out quite well, I will lead fill the joints and and though it will weigh a lot more than original it will do the job

(https://i.postimg.cc/mgkxDmby/EE70-E5-F5-A414-4-E82-ADAE-3-D2-A370-FFF3-F.jpg) (https://postimg.cc/nCySSY9X)

I got the engine head studs back from the plating shop and torqued down the studs and installed the piston, waiting on the machine shop to finish the head

(https://i.postimg.cc/cHmTfNhg/067214-DE-9-BCE-46-F8-8357-4-E3058-CA72-FD.jpg) (https://postimg.cc/7G5gydpw)

(https://i.postimg.cc/W3jXD4Gc/C80581-BF-2733-450-A-84-A2-1-BCD6-DA6-EC7-E.jpg) (https://postimg.cc/f32xpDq8)





Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 04, 2023, 06:16:04 PM
A nice used set of clip-ons came in the mail today from Flagstaff AZ, they were described as coming off an Ala d'Oro and look very similar to what I have seen on the Ala Verde bikes.

(https://i.postimg.cc/WbZytk15/IMG-5730.jpg) (https://postimg.cc/0b8nBrmS)

(https://i.postimg.cc/dVKxCV7w/IMG-5731.jpg) (https://postimg.cc/4mBPkZbS)

A nice fellow in the States sent me an Ala Verde (61 Harley Sprite) center stand with the only request I make a pdf file of it o that others could replicate it. The stand is very corroded but salvageable, the legs are cast, welded gussets and center tube

(https://i.postimg.cc/NFKPYyKv/IMG-5732.jpg) (https://postimg.cc/LgMV38kx)

(https://i.postimg.cc/wBzPJTGD/IMG-5735.jpg) (https://postimg.cc/LJyNFRRs)

(https://i.postimg.cc/XYdmpyQV/IMG-5734.jpg) (https://postimg.cc/5X9nryhG)

I have made CAD files to try and get some pieces water jet cut and fabricate a copy

(https://i.postimg.cc/C50Hrzb4/Aermacchi-Side-Stand-17-WHEEL-1.jpg) (https://postimg.cc/4789m4LK)

(https://i.postimg.cc/T1cjzf9v/Aermacchi-Side-Stand-17-WHEEL-2.jpg) (https://postimg.cc/jnLJNVmM)

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on April 04, 2023, 06:23:39 PM
Looks great, Jim.  How are you planning to replicate the cast I-beam cross section pieces- weld & grind or mill the centers of a thicker piece of steel?  I’ve got a coach builder friend who welds and grinds a lot of pieces to replicate obscure castings on high end projects.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 04, 2023, 06:35:23 PM
Looks great, Jim.  How are you planning to replicate the cast I-beam cross section pieces- weld & grind or mill the centers of a thicker piece of steel?  I’ve got a coach builder friend who welds and grinds a lot of pieces to replicate obscure castings on high end projects.

Hi Clint, I was thinking I would get the legs water jet cut then try milling out the centers with a ball end mill then heat and bend the 7 degree kinks in the legs.
The thing is I got this stand offered to me for free if I made up plans to replicate it and I offered to try and fab one for the guy who donated the stand but stretched for later model Sprints with 18" wheels. A couple days later a fellow in Italy responds on Facebook he has a good spare one to sell along with a bunch of other things I needed like a rebuilt pair of shocks, triple clamps for the clip-ons. I will go ahead and try my hand at making the longer stand for the guy who gave me the original, with a jig on a steel plate it shouldn't be too difficult.
I did find on Italian Ebay what I think are another pair of fork shrouds that I can rework for the clip-ons and keep the originals.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on April 04, 2023, 07:53:58 PM
Your generous offer situation sounds familiar..  I’ve gotten into a couple of deals like that.  The Italian connections sounds great, especially the center stand and triple tree.  Having spares won’t hurt.

I was looking at your pics, trying to see the likely spot welds attaching the ears to the shrouds.  I was thinking the headlight ears might be reproduced before you cut them from the tubes by making a mold, then casting a positive to use as a hammerform. Some parts are better suited for hammer forming than others.  They would only grow by the thickness of the metal you’re using if you pull a mold from the outside.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 05, 2023, 02:59:48 PM
Your generous offer situation sounds familiar..  I’ve gotten into a couple of deals like that.  The Italian connections sounds great, especially the center stand and triple tree.  Having spares won’t hurt.

I was looking at your pics, trying to see the likely spot welds attaching the ears to the shrouds.  I was thinking the headlight ears might be reproduced before you cut them from the tubes by making a mold, then casting a positive to use as a hammerform. Some parts are better suited for hammer forming than others.  They would only grow by the thickness of the metal you’re using if you pull a mold from the outside.

I have not got the extra fork shrouds yet but what I am hoping is I can mill off  3 ~ 5 mm from the underside of the upper triple clamp and the cut down the fork shroud to the top edge of the headlight bracket, if it works there would be enough room to fit the clip-on between the underside of the triple and the top of the shroud and leave just enough room to fit a new steel cap into the top of the shroud and tack it to the sheet metal of the shroud.

Once the parts arrive its time for some careful measurements.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 12, 2023, 07:30:55 PM
All the parts I bought recently to convert the front end to Ala Verde spec are now in hand
The rear shocks are very nice restored originals, super pleased with getting these parts.

(https://i.postimg.cc/wvd4smS1/36-B07-B28-9-FE3-4-FC8-901-A-5-E5672-F77-A38.jpg) (https://postimg.cc/zL0FsVDN)

Next to get to work on modifying the fork shrouds, first to separate the headlight ears from the shrouds, shorten the shroud, make new top caps and then re-weld the ears. I am looking forward to this step.

I sent the rest of the frame parts off to be media blasted and given a coat of primer powder so I can reassemble for the dry build.

(https://i.postimg.cc/W4Zf3nfR/2-A5-FAC0-D-9-D5-F-4-A8-E-9-F2-D-3731278-C48-E9.jpg) (https://postimg.cc/8F1bXhSw)

The machine shop I use is having a problem with cutting the valve seats so the head is off to another shop tomorrow that tell me they won’t have a problem as they have the correct stones and shaft to fit the valve guide, fingers crossed

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 14, 2023, 09:31:50 PM
This is what I need to modify, the clip-on bar neck is 30mm tall so the fork shroud needs to be reduced in height the corresponding dimension. It is not a simple matter as cutting the fork shroud down 30mm as the welded on head light ear is attached less than 30mm from the top of the shroud and the upper half of the shroud is tapered.

(https://i.postimg.cc/kMsDCfyy/05-AFD1-CF-CA98-4-DBA-BE0-E-064503-E843-CB.jpg) (https://postimg.cc/yWJ7XhtJ)

So the plan is to remove the headlight ear with an Autobody reciprocating saw and the re-weld the headlight ear lower down the shroud and make a new steel cap for the shroud through which the 30mm diameter fork tube passes. I made a steel tube section to fit inside the lower shroud section and chucked the shroud in the lathe with copper sheet as a buffer to the chuck jaws and I turned a piece of aluminum to fit into the 30mm hole in the top of the shroud.

(https://i.postimg.cc/FKS7QvPf/64-E383-CB-5-A94-4830-9-D5-F-030-F4-A827429.jpg) (https://postimg.cc/1g99pk1P)

Saw and cold chisel to split the spot welds. Then I cut 33mm off the shroud in the lathe.

(https://i.postimg.cc/FFVkR9h3/88-C90-ACF-853-A-444-F-9-F12-1018-FD76-E092.jpg) (https://postimg.cc/K448phk8)

From a steel billet 50mm diameter I turned new caps that sit 3mm above the cut off shroud and 6mm stepped inside.

(https://i.postimg.cc/8PkJfqC3/401-E24-F0-711-A-4198-B0-DF-90-DA879-B4-C33.jpg) (https://postimg.cc/ThSYZNgq)

I then welded the new cap to the shroud and repaired by weld any damage to the shroud from removing the headlight ear.

The rebuilt shorter shroud next to an original

(https://i.postimg.cc/13f8Jwwr/A7-FB4-B78-7715-4332-B8-EC-6944-D58-DBDB2.jpg) (https://postimg.cc/cvG1JKDv)

And mounted in the triple clamp with 30mm O rings either side of the clip-on bar.

(https://i.postimg.cc/t4Mxj2pc/0112-A54-E-8-CBB-407-B-A6-D2-5-A31-EBCA9-B3-C.jpg) (https://postimg.cc/bZ1J00G0)

It worked out very satisfactory and I finished the second shroud to match. Next to repair and revels the headlight ears in place. I have a second set of shrouds with identical headlight ears but different shroud dimensions that I will carefully cut the ears off and then weld to the shroud.

The center stand and shock absorbers along with the triple clamps I bought from Massimo in Italy have made this Ala Verde tribute possible.

(https://i.postimg.cc/0yDhDHrg/BC451566-87A4-49DA-9923-4C8A2BE6E631.jpg) (https://postimg.cc/LJ4yMDzv)




Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 15, 2023, 04:47:41 PM
removed a set of headlight ears from another set of shrouds, drilled out the spot welds, straightened up the sheet metal and welded the headlight eras to the shrouds, it will be convincing enough, I like the stance of the bike with the clip-ons but its going to be a bear to ride for an old fart like me.

(https://i.postimg.cc/4xCm8M0Z/IMG-5834.jpg) (https://postimg.cc/tY5qJrym)

(https://i.postimg.cc/5yY2gqq6/IMG-5838.jpg) (https://postimg.cc/H8mmsMNg)

(https://i.postimg.cc/br7NBD3L/IMG-5840.jpg) (https://postimg.cc/JHQLynwB)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 18, 2023, 09:17:47 PM
The Ala Verde tribute dry build continues ....

(https://i.postimg.cc/GmW1snGd/AFC74-AB9-A8-D3-4-DF7-AB27-F70-E3-D6-EEF54.jpg) (https://postimg.cc/pmJSg7s6)

I opened a box of reproduction rubber parts I bought from Italy and the foot rests stamped "Aermacchi / Harley Davidson" will not fit the riders foot rests that came stock on the North American market Aermacchi bikes. The Harley marketed machines have a robust foot peg that folds up and has a complex mount bracket to the frame with notched mating parts to adjust the height of the pegs, very nice!

(https://i.postimg.cc/Dyzh9g7k/0D7D32D3-5200-4159-AD56-E232D0895F1F.jpg) (https://postimg.cc/Wtxxr0DX)

Just when I think I have the Ala Verde thing figured out a new glitch pops up...

I have learned European market bikes have a rigid foot peg, the shaft is about 5/8" diameter,

My friend in Italy who has recently provided me with some rare parts for this bike sent me these pictures today of the Ala Verde foot rests

(https://i.postimg.cc/mgcCLJQQ/46E67654-81BD-4B7B-BA00-BC8EAE321CA6.jpg) (https://postimg.cc/zyrVpd2B)

Massimo is going to send me detailed pictures of his Father's 1961 Ala Verde foot rests and close ups of the frame mounts.

I can make copies of the European foot peg easily enough.

I also found out I don't have the seat mounting rear bracket correct, the Ala Verde doses not have the exposed vertical straps at the rear, only a single bolt trough the top of the rear fender.

(https://i.postimg.cc/nrG3Q24N/E17-C72-C2-3-B9-C-49-A5-880-B-5-F3-A5-E98-F3-EE.jpg) (https://postimg.cc/PvNWgmFM)

I am getting closer to solving the puzzle.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 22, 2023, 07:02:55 PM
I made up a copy of the Aermacchi center stand, a version for bikes with 18@ wheels and a copy of the original for 17” wheels

(https://i.postimg.cc/151Bj6p6/3E186BB1-E34D-42E2-A305-FDEC3935C2AC.jpg) (https://postimg.cc/BtN28j7Q)

I made plans in AutoCAD and had the plate pieces water jet cut from 10mm plate and 5mm plate, the center dowel is 19mm solid rod. I made a welding jig using an original stand to make the jig.

(https://i.postimg.cc/g0s1YsHf/69C41F2B-F4EB-404A-8F05-9A9527AB323A.jpg) (https://postimg.cc/d77568XB)

I cut the recesses into the side plates on my milling machine

(https://i.postimg.cc/7h2BTnSP/1096A32A-461D-48FD-9F6A-3070268B62F4.jpg) (https://postimg.cc/64BVkRHF)

Lots of fiddling, grinding and welding

(https://i.postimg.cc/tCFSqDX2/340A4F4B-3195-45BF-969E-89967DEB9F89.jpg) (https://postimg.cc/BXQcNTPK)

Needs some finishing of welds but it’s a decent facsimile of the original

(https://i.postimg.cc/brkTvNjs/51FBFF43-1A0D-47DA-82F3-4274A487674D.jpg) (https://postimg.cc/n9V7RxrJ)

(https://i.postimg.cc/YCCmjq6j/692EAB7E-2274-4E88-8F0B-8521EECCDFB0.jpg) (https://postimg.cc/YhTSs7yw)
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on April 25, 2023, 08:26:17 PM
That’s a lot of progress- looking great, Jim!
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on April 25, 2023, 08:51:42 PM
That’s a lot of progress- looking great, Jim!

Thanks Clint!

I have found what I think are the last bits I need from Sonny’s Aermacchi Sprint in MA. I need to make custom length push rods to adapt the pre 67’ head to the 68 short stroke bottom end but I think that will be straight forward

Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on May 09, 2023, 01:16:54 PM
The Ala Verde foot rest brackets differ from the typical Sprint style, to begin with they do not fold up nor do they rotate on their mount to change position.

These are the stock US Import style, very well built and clever design how the castellated mating pieces allow for easy peg height adjustment.

(https://i.postimg.cc/vDFHmpN3/IMG-5951.jpg) (https://postimg.cc/YLRwnykW)

The Ala Verde type cast pieces, provided to me once again by my friend Massimo in Italy! Thank you so much for sourcing these for me.  :bow:

(https://i.postimg.cc/xTMLPYnj/IMG-5954.jpg) (https://postimg.cc/3dryKskz)

(https://i.postimg.cc/wv1mRYwp/IMG-5958.jpg) (https://postimg.cc/fthL1p42)

(https://i.postimg.cc/zGw3yG5W/IMG-5955.jpg) (https://postimg.cc/dh1JXvht)

and with the reproduction Ala Verde type foot peg rubbers

(https://i.postimg.cc/bYbRm1Rj/IMG-5962.jpg) (https://postimg.cc/0rkmQM3t)

(https://i.postimg.cc/vHhfKhgC/IMG_5967.jpg) (https://postimg.cc/HVJrcQtt)

little details, but they all add up, I feel like I won a lottery lately finding these Ala Verde unique bits.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: cliffrod on May 09, 2023, 08:05:22 PM
These details are fantastic, Jim.   Thanks for clarifying and posting so many of them. I bet those solid foot pegs are a lot nicer for serious riding than the typically super floppy footpegs on regular Sprints.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on May 10, 2023, 09:53:52 PM
These details are fantastic, Jim.   Thanks for clarifying and posting so many of them. I bet those solid foot pegs are a lot nicer for serious riding than the typically super floppy footpegs on regular Sprints.

Thanks Clint

Next job is to take the seat cover off the frame and make adjustments to the steel perimeter frame and add a curved rear loop and a hoop section to better support the hump. I saw a photo of an actual Ala. rede seat frame, my seat frame is from a Benelli ( I think), the cover is a proper Ala Verde reproduction but I think I can get it to look better. From Sonny’s Aermacchi I got a hold of a set of original NOS Harley Sprint early 60’s cables that have the clamp on ends that I can cut to suit to fit the clip-ons.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Dave Swanson on May 15, 2023, 09:04:19 AM
Wonderful project.  I've been enjoying it.  I have had a 73 SX350 around for a long time waiting it's turn.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Canuck750 on May 16, 2023, 02:12:07 PM
Wonderful project.  I've been enjoying it.  I have had a 73 SX350 around for a long time waiting it's turn.

I like the 73 ~ 74 HD Aermacchis a lot, electric start and the dual pipe exhaust is a real plus.

Getting parts for the Aermacchi bikes is getting harder and harder, if you think your Aermacchi may need something I suggest you scoop it up while stock is available. Ebay and Sonny's has been the best source since Moto Italia and Lancaster Aermacchi shut down last year, Pool's Cycle in Hamilton Ontario Canada is another good place to check on Aermacchi parts, long time HD dealership since the 40's has some hard to find NOS parts for me.
Title: Re: Little Green Wing - Aermacchi Ala Verde
Post by: Dave Swanson on May 17, 2023, 09:29:24 AM
I like the 73 ~ 74 HD Aermacchis a lot, electric start and the dual pipe exhaust is a real plus.

Getting parts for the Aermacchi bikes is getting harder and harder, if you think your Aermacchi may need something I suggest you scoop it up while stock is available. Ebay and Sonny's has been the best source since Moto Italia and Lancaster Aermacchi shut down last year, Pool's Cycle in Hamilton Ontario Canada is another good place to check on Aermacchi parts, long time HD dealership since the 40's has some hard to find NOS parts for me.

Duly noted!  You have spurred me into action.   And it's a 71 not 73.  I always forget.