Floor(board) it! In which I replace the Vespa Smallstate's floorboard.

This is a long video for me, but that's because it covers a lot of ground: Completely replacing the floorboard, with my various mis-steps along the way.
This was by far the most aggressive bodywork project I've undertaken, and it probably shows in the journey, though hopefully not too much in the results.
Music: Also Sprach Zarathustra (feat. Richard Strauss) by Sascha EndeWebsite: filmmusic.io/song/5730-also-s... under CC BY 4.0: filmmusic.io/standard-license

[@regd.2263]

You should have cut the floor panel the full length in half then match it with the original legshield, then fit a new piece of metal in the middle it would have saved you having to alter the edges of the existing legshield.

[@ChandlerHowell-Vespa]

Perhaps, but would also have added a TON of additional butt welding, which I'm pretty bad at. Plus I'd have needed new, wider cross braces and the whole thing would have spun out of control pretty quickly.

[@regd.2263]

I'm fitting a new complete legshield to a 1960's Douglas Vespa 150 Sportique I myself have some problems mostly surface rust in the frame tunnel I'll be doing that at some stage

[@ChandlerHowell-Vespa]

@@regd.2263 Keeping the metal from pulling back when welding was brutal. I need to get a TIG setup if I'm going to be doing much more sheet metal work. It would be pretty handy for working on cases, too. The spool gun MIG only gets me so far.

[@ChandlerHowell-Vespa]

@@regd.2263 That rust would have to be pretty bad before I'd cut open the tunnel. You can do a LOT with flexible brushes and spraying ospho, then shooting self-etching primer in there. No welding required. That's how I handled it on my GL.

[@WestCoast-bp3uh]

Mate ,don't grind anywhere near your scooters. or anything you don't want to imbed tiny shards of moltan metal into..... I hate to break it to you but you probably ruin the paint work on all your beautiful scooters ,you'll see it when it starts to rust......damn😵‍💫

[@ChandlerHowell-Vespa]

Luckily, it's four humid months since then and no signs of problems so far. That OG Vespa paint is TOUGH. I generally do try to avoid grinding or sanding inside the workshop, but that's so I don't make a mess in there.