Scooter restoration: Vespa, Lambretta and commuter classics

Classic scooters hide rust in places you do not expect. The floor, inner leg shields, battery box and the channel where the side panels sit all rot from the inside out.

Panel work first. Most classic scooters are monocoque steel, so straight panels are structural. Replace a rotten floor section before you worry about paint. Leg-shield dents are easier to repair while the headset is stripped.

Engine and transmission. Two-stroke engines are simple but unforgiving. Check the crank seals, piston, bore and bearings. A seized engine usually needs more than a new piston. Renew cables, the carb mount and every oil seal.

Electrics and loom. Scooter looms are short but cramped. Route new wiring carefully so it does not chafe against the frame or the seat catch. Upgrade the earth paths while you are in there.

Wheels and suspension. Rebuild the front fork with new bushes and dampers. Fit a decent tyre, not a hard old wall hanger, and replace the brake shoes.

Finish and trim. Badges, floor runners, seat trim and screen rubbers make a scooter look right. Buy the best quality you can — cheap chrome and plastic trim lets the whole job down.