At long last I am actually doing some real work on my ’68 Puch 250 SGS. I replaced the oil in the tank with some TC-W3, and I think I’ve burnt off all the old 10-w30 that was lingering in the system, much less smoky now.
I’ve fitted the choke plate and it works great, the bike is a 2-3 kick start; replaced the lower bolt on the chain guard (flowed the brazing to remove the old bold, re-brazed a new one on; filled holes and primed the nacelle; repaired a crack in the fender, banged out a few of the dents, and slathered on a liberal coat of Bondo.
I initially experimented with trying to stick weld the sheet metal, I know it can be done, but it is out of my skill range and I don’t have the time to practice. I did fill one hole on the nacelle but opted to brass braze the others as it is faster and well within my skill range.
It is hard to articulate just how badly dented the front fender is, it resembles a sheet of paper that has been crumpled and smoothed out again, the shape is there more or less, just very lumpy. This can be seen in the picture where I ground off the paint before the resin filler. I’m using a quick-set filler, must say I love it, really speeds up the fill/ sand cycles.
The fender will make a thud sound when finished rather then the nice ringing ding of an all steel fender. I suppose I could buy a less abused fender off ebay, but that wouldn’t be quite right.