Winter Chaly Project

TUFTYNUTKIN · 2014-03-22T00:31:22+00:00

So this is it I have had this Chaly for about 2 years and it is time to bring it back to life, the engine runs and it all works but as these are quite common now I have decided to give it a new lease of life. I will be posting pictures as the project moves forward, I look forward to your comments both positive and otherwise. I intend to keep it as mechanically stock as possible but some of the parts will need to be replaced as they u/s. The chrome looks good in the photo but it needs rechroming as it is a bit flakey, CSML sell parts for these minibikes and claim they are original but the rack on mine is different to theirs and also the handle bar tree on mine has 2 fittings one for the ignition switch and one for the light switch where as theirs only has the one for the ignition switch. Not sure about the colour scheme yet, maybe a baby pink frame with pink carbon accessories and a white shag pile seat !!!!!!!!!!!!!!!!

Started by TUFTYNUTKIN · 14 replies · 6608 views

TUFTYNUTKINStandard MemberPosts: 456
Joined: Mar 2009

Re: Winter Chaly ProjectTue Jun 17, 2014 9:34 pm

Hi
So updates,
The front forks have been totally refurbished wit all chroming redone and guides bushes and other bits replaced with new, the only reused untolested parts were the springs which I ultra sonic cleaned and then regreased.
I repaired the main loom due the numerous cracks and poorly repaired joints these were all remade and heatshrinked(I don't like taped joints) fortunately on the Chaly there are lots of locating tabs and grommets so refitting accurately was a breeze.
I have added some pics in glorious colour of the assembled front forks and the loom and battery box fitted in the frame (the battery box has been powder coated as have lots of other bits)
Regards Tufty
P.S The pic's are in colour

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BlueModeratorPosts: 468
Joined: Jun 2011

Re: Winter Chaly ProjectTue Jun 17, 2014 10:02 pm

Nice, did you get the lower front legs rechromed? Is so where and how much

TUFTYNUTKINStandard MemberPosts: 456
Joined: Mar 2009

Re: Winter Chaly ProjectTue Jun 17, 2014 10:07 pm

Hi
Yes I did get them rechromed by RS Chrome in Manchester I don't know how much just the forks were as I got them done with other parts but you can go on there website but return postage is £16.00 + VAT as I said in other posting it is sometimes cheaper to get new and these parts are still available.
Regards Tufty
P.S have you got any of your collection up and running ????????????

WaynusModeratorPosts: 1108
Joined: Feb 2009

Re: Winter Chaly ProjectTue Jun 17, 2014 10:25 pm

It appears to be a very high quality paint job!

TUFTYNUTKINStandard MemberPosts: 456
Joined: Mar 2009

Re: Winter Chaly ProjectSun Jun 29, 2014 8:09 pm

HI
I have now received my chroming back so I can hopefully move on but just a pic to show that I have not just been working thou it feels like it, I will never moan about fitting the original air filter can again on my Dax as fitting the original back in a Chaly is a nightmare as it right down inside the frame hopefully the pic will show this.
Regards Tufty

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