Author Topic: Little Green Wing - Aermacchi Ala Verde  (Read 2994 times)

Offline Scout63

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #30 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.
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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #31 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!

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #32 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.
48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #33 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.



cleaned up for welding



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













48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #33 on: September 26, 2022, 02:43:04 PM »

Online Dave Swanson

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #34 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
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Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #35 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.





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.



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.

48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #36 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



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



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


48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline cliffrod

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #37 on: October 11, 2022, 06:58:32 PM »
Looks really nice, Jim.  Glad you were able to find those covers while you were there.
1973 V7 Sport  "Now THAT'S a motorcycle!"-  Master Sculptor Giuliano Cecchinelli
1967 V700 Corsa Record
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Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #38 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?
48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline cliffrod

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #39 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 Iím still learning- invisible flame, extremely low pressure like 2 psi.  But itís 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 youíll have lots more difficulty producing good work.  Thereís 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 wouldnít even consider gas welding it.  Much less chance of blowing holes because a much more finite area is heated/penetrated, so the whole piece doesnít 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.
« Last Edit: October 12, 2022, 07:40:46 PM by cliffrod »
1973 V7 Sport  "Now THAT'S a motorcycle!"-  Master Sculptor Giuliano Cecchinelli
1967 V700 Corsa Record
1981 Lemans CX100
https://www.youtube.com/watch?v=ExX3YmQel_Q
http://carolinasculpturestudio.com/
Carolina Sculpture Studio YuoTube Channel-
https://www.youtube.com/channel/UCzSYaYdis55gE-vqifz

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #40 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 thatís 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.
48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline cliffrod

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #41 on: October 12, 2022, 09:07:41 PM »
If you have room for a bigger/older machine, thereís good deals on AC/DC TIG welders now that people keep switching to the smaller inverter welders.  Iíve 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 donít know where they need to be setÖ.  Donít 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.  Itís just not what they're used to using so they donít want them.  Says itís 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 $$.   
1973 V7 Sport  "Now THAT'S a motorcycle!"-  Master Sculptor Giuliano Cecchinelli
1967 V700 Corsa Record
1981 Lemans CX100
https://www.youtube.com/watch?v=ExX3YmQel_Q
http://carolinasculpturestudio.com/
Carolina Sculpture Studio YuoTube Channel-
https://www.youtube.com/channel/UCzSYaYdis55gE-vqifz

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #42 on: October 12, 2022, 09:51:30 PM »
Thanks again Clint, I will check with a couple welding supply shops here.
48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #43 on: November 24, 2022, 05:20:20 PM »
The Ďsecondí 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



Welded up from both sides





Plenty of work with a die grinder, file and sanding and itís pretty damn good

48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline cliffrod

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #44 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 didnít 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.
1973 V7 Sport  "Now THAT'S a motorcycle!"-  Master Sculptor Giuliano Cecchinelli
1967 V700 Corsa Record
1981 Lemans CX100
https://www.youtube.com/watch?v=ExX3YmQel_Q
http://carolinasculpturestudio.com/
Carolina Sculpture Studio YuoTube Channel-
https://www.youtube.com/channel/UCzSYaYdis55gE-vqifz

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #45 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 didnít 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.

Youíre 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



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 Georgeís 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 Georgeís 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.
48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline Canuck750

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #46 on: November 25, 2022, 04:04:13 PM »
Seemed like a good time to mount the 'new' side cover onto the right hand side



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



I hope to make some serious progress on the Macchi this winter.
48 Guzzi Airone, 57 Guzzi Cardellino, 65 Benelli 200 sprite, 66 Aermacchi Sprint, 68 Gilera 106 SS, 72 Eldorado, 72 Benelli 180, 74 Guzzi 750S, 73 Laverda SF1, 74  Benelli 650S, 75 Ducati 860GT, 75 Moto Morini 3-1/2, 78 Moto Morinii 500

Offline Frenchfrog

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #47 on: November 26, 2022, 04:39:37 AM »
Stunning work !

Offline cliffrod

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Re: Little Green Wing - Aermacchi Ala Verde
« Reply #48 on: November 27, 2022, 08:21:02 AM »
Itís looking great, Jim.
1973 V7 Sport  "Now THAT'S a motorcycle!"-  Master Sculptor Giuliano Cecchinelli
1967 V700 Corsa Record
1981 Lemans CX100
https://www.youtube.com/watch?v=ExX3YmQel_Q
http://carolinasculpturestudio.com/
Carolina Sculpture Studio YuoTube Channel-
https://www.youtube.com/channel/UCzSYaYdis55gE-vqifz

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