Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

https://www.treatland.tv/peugeot-103-70cc-47mm-metrakit-w-head-p/peugeot-metrakit-010810247.htm

Anyone else building one of these? I know Tomahawk built one, but he keeps his secrets pretty close.

I'm a cheap bastard and the $120 price tag for a kit that I know and love with a decompless head seemed too good to be true. BIG ASS vertical fins, thicc nasty head, gotta be a dope air cooled rig, amirite? Naturally, i totally ignore treats disclaimer at the bottom because how bad could it be? lel RIP

I'm probably 8 or so hours (maybe more maybe less idk, most of it is drinking beer and getting metal shavings out of my eyes) into building it and it's been a lot of work. but i'm very excited.

I "bored" the case with a big sanding drum (1.5" i think) on a drill and it worked surprisingly well and I am pleased with the results. I hand bored a bat case way back in the day with a dremel and i think the drum method is much more consistent and provides a better result. Big drum removes material very evenly. I kept test fitting the Cylinder and removing the high spots that get shiny when you try to jam the bitch in. I Used the spacer that treats sells as a guide for the bore diameter.

The fins in the back are easy, i just cut them a bit with an angle grinder. you don't need to remove much and it's only the outer two that would hit the motor mounts.

Even with the spacer, The cylinder skirt is too long to fit into the polini cases without collisions; im not sure about the stock cases, but i imagine it's similar. so i cut off about 25% of it and now it fits very well.

I rough cut the big polini transfers into the spacer last night and plan to open the transfers on the kit itself to match. Lot of dremel work to do still.

The boom boom zone of the 50cc head it comes with is too damn small, so i used the included head gasket to mark the diameter for the 70cc piston. I screwed a sparkplug into the head upside down and used the threaded nipple to chuck it into my small af drill press and spun the head while working it with a dremel. the shit chatters all over so you get really terrible "machining" marks, but it cleaned up really well with some sand paper. I'll lap it on some glass when im pleased with the profile.

I'll try to grab more pictures tonight. I have been really bad about documenting this.

IMG_20191020_151247.jpg

I'm doing all this just to run stock points, stock trans, a stock pipe and idgaf. they can hear me motor grunting from 3.5 blocks away. oh lawd he coming (edited)

Re: Peugeot 103 70cc Metrakit

nice!

yah i've thought the same thing, great kit, killer price. cant wait to see how it turns out.

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

> Graham Motzing Wrote:

> -------------------------------------------------------

> cant wait to see how it turns out.

8478dbeca8e8fc463ea0edf35cfc92d7.jpg

Re: Peugeot 103 70cc Metrakit

> DrGeorgeTompson (Alan) Wrote:

> -------------------------------------------------------

> > Graham Motzing Wrote:

>

> > -------------------------------------------------------

>

> > cant wait to see how it turns out.

> >

LMFAO at the burning bike pic (edited)

Re: Peugeot 103 70cc Metrakit

Stock pipe you say.....hummmm

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

> Baron Von Hamilton Wrote:

> -------------------------------------------------------

> Stock pipe you say.....hummmm

It's derestricetd; it's totally fine

<.<

>.>

<.<

Re: Peugeot 103 70cc Metrakit

I’m into it! I know you could not tell by my message but that was curiosity. How does it look?

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

> Baron Von Hamilton Wrote:

> -------------------------------------------------------

> I’m into it! I know you could not tell by my message but that was

> curiosity. How does it look?

lol i have no idea yet. I know on the page for the kit it says you'll need to figure out the exhaust since it's a different angle or something. It's a pretty easy pipe to work with since it's just soop can

I'm not even sure if the stock piep will work with polini spring and stuff ( i realized it probably wont like 3 days ago after i already bought everything). Shouldnt be super hard to work around. I haven't gotten that far yet ¯\_(ツ)_/¯

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

Comparing to the pictures on treats or maybe your photographic memory of what the metrakit skirt looks like, you can see below how much i took off. Is it going to be problematic? maybe probably. It'll just be a slappy boi. dropping the piston into the bore with the spacer and no gaskets, it sits on the case about 10mm below the end of the skirt. the piston is probably 1-2mm south of the bottom of the exhaust port. Once i am pleased with the porting and shit, and finallly put the crank in, i'lkl figure out how much i need to butcher if any.

IMG_20191028_185726.jpg

Here's the head after hillbilly cutting. I positioned it just so you can't see the part that looks the worst very well. tbh, i think it turned out pretty well for how shit my tools are.

IMG_20191028_185746.jpg

Machinist's dye is cool for marking stuff, but my hands have had blue spots on them for days.

Re: Peugeot 103 70cc Metrakit

Your doing fine. That head though might give you way too much compresion thus turning into a lot of heat. You can always cup out the center later if it proves to radical

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

yeah, i am worried about that. Not so much that it will be hot, but that i wont be able to push start it without bussin a hernia. It's a pain enough to start with out the decomp on the stock top end lol. I am fairly opposed to running a pull start because i am convinced that's why my hobbit was stolen.

It shouldn't be terrible to fix though. I'll get that all figured out once the bottom end is together and I can measure the squish and be disappointed with my work.

Re: Peugeot 103 70cc Metrakit

If you mod the starter shoes to have less material it spins up more and can build more momentum before grabbing and grabs harder.

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

> Daniel '' Wrote:

> -------------------------------------------------------

> If you mod the starter shoes to have less material it spins up more and

> can build more momentum before grabbing and grabs harder.

I have been reading non-stop about pugs since i picked this one up. I saw the write up on removing a large portion of the shoes to do that. I've already modified the clutch weight and it definitely just shits the bed after the starter engages. It recovers eventually. It's interesting that i didn't really notice them until I ported the stock exhaust. I guess before it was just a slug all the time and not super noticeable.

Out of curiosity, has anyone ever tried cutting sipes into the shoes instead of removing a square chunk? Or is it all the same effect and doesn't matter?

anyways, gonna trim the shoes a bit next time I take the variator off.

Re: Peugeot 103 70cc Metrakit

I don't know about little sips , but , it seems brake shoes do better with grooves cut in them .

Why wouldn't the same apply to like shoes in other applications ?

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

So here's the ever so familiar metrakit transfers. They are very wide but not as tall as the Polini race case. I'm not sure what i marked here. I think that's the gasket that comes with the kit.

IMG_20191028_185809.jpg

if the spacer was not there, the kit transfers are way wider than the polini cases, there would be a giant hole on both sides of the base. You can see how much over hang there is. It's like that on both sides

IMG_20191028_194938.jpg

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

Bearing all that in mind, I really can't/shouldn't widen the kit ports. Which has lead me to this to match the height of the case transfers.

IMG_20191028_194246.jpg

However, i am still facing the problem of the big-ass wide load transfers. My plan was to taper out the spacer to match the kit but won't that still be all wonky, flow-wise? I mean i guess it's better than a 90 degree angle. The spacer is also pretty damn thick and it might be the best route. I dunno. It will end up being a pretty thin sealing surface around the points if i do but yolo. I am not inclined to try to make the transfers smaller with jb weld or some tweaker shit.

IMG_20191028_194933.jpg

I did a similar weirdo tapering on the batavus i kitted forever ago since the m01 kit ports are little bit wider than the edge of the bat case or wahtever, spacer life. That shit lives on somehow and moves pretty good.

Pay no attention to the beer marks in the case. I'll buff them out at some point. (edited)

Re: Peugeot 103 70cc Metrakit

Use the spacer to taper it in, it is totally the way to do it. Unless you want to weld up the cases that is.

Re: Peugeot 103 70cc Metrakit

Jansen Hanzer /

yes I have done this

I used the malossi case and made my own spacer

a Peugeot pipe using spring mounted header bolts right up to the derbi kit

you will destroy everything on your bike with this kit so be prepared

easily the best kit for Peugeot

ok thank you for reading

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

> Jansen Hanzer Wrote:

> -------------------------------------------------------

> yes I have done this

>

> I used the malossi case and made my own spacer

>

Did you need to cut the skirt off for the Malossi cases? I'd imagine so.

> a Peugeot pipe using spring mounted header bolts right up to the derbi

> kit

>

I am going to hold off on getting a pipe for as long as I can. The only reason I picked up this bike is because my Derbi is loud as fuck and annoys the yuppies on my commute. Also launch levers are cool as shit.

> you will destroy everything on your bike with this kit so be prepared

lit. I like when stuff breaks cause i get to fix it.

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

I'm done with this stuff for now. Bringing it home to wash in the sink and prepare for bottom end assembly.

IMG_20191029_195108.jpg

The blue shmoo is pretty great for marking gasket paper. I just slather it on the surface and press it against the paper before it gets a chance to dry. I did it on bubble wrap and i think that helped make the edge lines sharp. Pretty neat.

IMG_20191029_190407.jpg

I have to figure out my base spacing and cut some gaskets to figure all that shit out. I have some dremel beer marks on the spacer that i might just fill will some jb weld or whatever. Might just put some non-hardening sealant in there. Flying by the seat of my pants

Re: Peugeot 103 70cc Metrakit

It’s gonna blasT! My moped burned like that in the middle of the street at our ire rally. Hahaaa

Re: Peugeot 103 70cc Metrakit

Jansen Hanzer /

yes I had to cut the cylinder skirt

ok thank you

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

So I finally got around to assembling the bottom end. It was pretty damn easy, and i got use my trusty road side toaster.

IMG_20191101_184115.jpg

I dont really know how the polini cases go together as i got them used a few weeks ago. There's not that many parts, i can probably finger it out. I ordered an extra set of bolts just to make sure i had extra long ones because i didnt want to figure out where they actually went.

Is the rubber mount thing that the spring sits in an exhaust hanger? it sure looks like it. Also the launch lever mounts differently than on the stock cases. neat!

IMG_20191101_192825_01.jpg

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

So the ports end up in an interesting spot.

IMG_20191101_191005.jpg

This is with no gaskets at BDC. It looks pretty normal at tdc with no gaskets actually.

IMG_20191101_191018.jpg

This is if the piston crown was level with the floor of the exhaust port. Piston is way low at tdc. Unless i deck the cylinder, this is not an option.

IMG_20191101_191113.jpg

I took some rough measurements and about 1.5 mm of gaskets will get me where i need to be. I'll probably cut one, measure squish and cut the second to pick up the slack.

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

Ok, so I ended up using way less base gasket than i thought. Putting a thicc helping of Dykem blue on the spacer and tapping the inked spacer on the gasket paper worked really well. I've gotten it down pretty well.

IMG_20191102_121436.jpg

If you don't have a punch set, you are doing it wrong. Makes so many holes so easy. I used to punch the base gaskets and to open the holes on the head gasket and exhaust gasket from this to fit. it was lit. Also note: that flange is angled so i can mount it the best orientation to fit the pipe. i think it's gonna work well.

IMG_20191102_121543.jpg

Initially i had cut a .5 and .85 gasket. I could barely measure the squish (@ ~2mm) with no head gasket (.5 mm). So i made 2 more at .3mm. The total gasket stack (including head) ends up a 1.1mm. The base spacing was (4.5+.6 = ~5.1mm) Probably closer to 5mm once compressed. and i may have taken some material off the spacer at some point but it's likely negligible.

Anyways, that leaves the squish at about 1.7mm the piston ring is just barely visible at bdc; the compression is right around 120psi. I'm kinda butthurt how low it is, but it will probably run forever if all goes well.

IMG_20191102_140838.jpg

The top end is comically larger than the bottom.

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

Some fun facts about the DAKAR carb.

The bowl that comes with it is alluminum and heavy as fuck at 75grams. The plastic dellorto bowls are 15 grams. I'll see if i have a plastic cap too, but i dont think i have one without the choke mech.

The Idle fuel air mix screw is interesting. There is no small idle hole like on a genuine SHA.

Instead is just pipes the fuel into the emulsion tube. I'm assuming thats why the adjustment ends up being so touchy. Either way, still a great carb.

I did have to file the float needle just a spell to make the float closer to level, but no biggie cause it is brass and fairly soft.

Also, this one had an issue with the clamp screw. it has a slight collar on it by the head and when tightening it, it would jam and not tighten the clamp anymore so the carb would rotate easily. I opened up the hole for the bolt just a hair on one side and now it is properly clamped when tight. I don't recall doing that on the previous DAKAR carb I bought but that was long ago.

Re: Peugeot 103 70cc Metrakit

> Daniel '' Wrote:

> -------------------------------------------------------

> If you mod the starter shoes to have less material it spins up more and

> can build more momentum before grabbing and grabs harder.

Haha I do this to e50 clutchs if they have a bump in the back

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

Haha sick. It's gonna work

IMG_20191103_120641.jpg

And by work, I mean fit. Still prolly gonna blow up right away (edited)

Re: Peugeot 103 70cc Metrakit

Brandon Weiss (Detective brandon to you) /

I tried using a Dakar 15mm sha on my derbi, but I could not get it to seal at the intake. I tried o rings, different shims, even one of those rubber grommet things that comes with some sha..no luck. Ditched it for a different setup.

Re: Peugeot 103 70cc Metrakit

DrGeorgeTompson (Alan) /

I got this fat boi9 mounted up and boy did i encounter issues. Nothing too crazy and I only caught myself with the grinding wheel twice.

My first problem was that the stock clutch starter bell hit the edge of the spacer. EZPZ just dremeled off a chunk. It's close but should be fine.

IMG_20191103_124905.jpg

Then I get to the stator side. I refreshed the points and condenser with new parts cause i was getting some arcing prior.

I had to trim those long ass bolts I had cause they got in the way. no problem. BUT THEN, the stater assembly was hitting the fins on the right side. I ground the piss out of them and boom, fitz. The le parti cdi prolly would fit without issue as it is smaller. It's an ugly job, but i no longer give a shit.

IMG_20191103_131433.jpg

Then i go to mount the motor and realize i had the launch lever in the wrong spot so it would not fit. It take it back off and fix that.

I go to put the back on and the head fins hit the frame so it wont swing forward very far. I may not have needed to cut them a bit, but i did anyways. So now it swings all good and shit.

I got to mount the rear spring and drill the hole in the wrong spot, then fix it and then strip the hole in the block. I heli-coil it which is probably good cause it's stronger than the aluminum. mounted.

Then i go to start it and have no spark so i have to chase that shit down and it seems like the new points had like a clear coat on them or something. Once i sanded and filed them everything was hunky-dory. Had spark shit started right up.

I rode it into the alley but the stock jetting is no good, so idk how it really it. Seems kinda wonky with the soft-ass polini spring; it really doesnt seem much different than the stock spring. The motor was bouncy when the clutch was engaging but i only really accelerated once before i went back. I trimmed the starter pads and it definitely grabs real hard a little later. kinda weird, but it should work.

now my lights aren't working. Whatever; i'll figure it out tomorrow. I was in the shop for about 7 hours today and i am pleased with my progress.

Stock pipe is mounted with the stock bracket and clampy thing. I have a piece of 1/8" flat bar connecting the soft mount to the bracket. It seems pretty solid but it will probably rattle itself off. I'll grab a picture later. Also, it's not really any louder, just sounds cooler.

IMG_20191103_185611.jpg

(edited)

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