How to install a front rack on a Buddy 125

michelle_7728 · Post by **michelle_7728** » Wed May 02, 2012 2:10 am

First the disclaimers:
1. I'm not a professional at installing stuff and definitely make my share of "oops's".
2. If I steer you wrong and you crack or break something, it's on you, so look at the below info and decide for yourself whether you feel what I am saying makes sense, is correct for your situation, and you are comfortable attempting it yourself.
3. Everything I state in this thread is IMO, and just what worked for me. I make certain assumptions (such as that all the cutout imprints on the front body panels of the Buddy 125s are in the same place relative to where the rack bolts on), but I might not necessarily be correct.

michelle_7728 · Post by **michelle_7728** » Wed May 02, 2012 2:14 am

What I did is not what I will be showing here (because I was able to take the front panel off my orange 2009 and verify that the holes lined up on the black 2009).

In my (limited) experience, both of my front panels needed the holes to be drilled up and to the left of center (of the factory "punch outs") by at least 3/16”.

You can maybe make a cardboard template, or you can drill slightly NW of center in the two locations, then when the holes get big enough (start out with a small drill bit, then work your way up to a larger one) like ½” across, put the cover back in place and you can get an idea where you need to keep widening your holes.

michelle_7728 · Post by **michelle_7728** » Wed May 02, 2012 2:20 am

With my black body panel, I used a silver Sharpie to mark the areas I still needed to widen with my Dremel. The key is to do it a little at a time, checking as you go.

Don't try to do the whole thing with drill bits, as you probably will not be able to get the holes completely lined up without taking more material off of one area or another.

DON'T do any drilling or (Dremeling) while the panel is sitting in place on your Buddy. I placed my panel on the ground (on a piece of cardboard) and had the outside (with the badging) facing me as I drilled.

If you take your time, use several drill bits (starting tiny, like with a 1/8" bit), and don't force anything, you shouldn't crack the body panel. I've never cracked any panels I've drilled into, but I've always been cautious and worked my way from a tiny hole to a larger.

When using the Dremel tool, I knelt in front of the panel and kind of braced it against my legs as I held it (the body panel) with my left hand. Not saying that's the best way, but that's how I did it.

You will probably want to make your holes a bit larger than you really need so that the plastic sleeves and bolts that will hold the rack in place don't tighten into your body panel and crack it....again, take your time and visually check things out as you go.

michelle_7728 · Post by **michelle_7728** » Wed May 02, 2012 2:21 am

Last picture. Whew!

david12df · Post by **david12df** » Wed May 02, 2012 2:40 am

just did mine on a bud 150 ,holes did not match up to plastic,
also rack did not match up to the brackets,took me and a friend
to pull and push so rack would get into holes
30 min.to install and plastic holes cut out by stevie wonder
using a rotozip

don't dare by the cowels they might be the same.

qballfc · Post by **qballfc** » Wed May 02, 2012 3:41 am

Sorry for the dumb question, but, how do you keep the rack down? I don't see anything to hold it down and when I checked one out at a scooter shop the springs seemed pretty strong.

hg3 · Post by **hg3** » Wed May 02, 2012 3:46 am

Michelle_7728,

Nice set of photos and instructions.

I am pretty sure this will make the Technical Library.

Harry

david12df · Post by **david12df** » Wed May 02, 2012 4:29 am

I use 1 zip tie to keep it open all the time

michelle_7728 · Post by **michelle_7728** » Wed May 02, 2012 4:33 am

hg3
Thanks. I hope they are helpful to folks.

qballfc
I just wrap a 8" piece of velcro around the top, then when I want it open, I wrap it around the bottom. That way you don't have to use/clip a zip tie...on the other hand, if you use the front rack all the time...

Skootz Kabootz · Post by **Skootz Kabootz** » Wed May 02, 2012 6:03 am

What you want to use for a round hole is a circular drill bit. I don't know the correct diameter off the top of my head but it will give you a cleaner hole.

Something like these:

I'm not sure why you are having such difficulty aligning the factory holes. Of the many Buddy's in dealerships and elsewhere that I have seen I have yet to see one that doesn't fit correctly as is with a front rack in place. If you keep the panel loose while you are aligning the front rack screws, get those threaded correctly and only then snap the front panel into place you should have no trouble.

michelle_7728 · Post by **michelle_7728** » Wed May 02, 2012 6:28 am

Interesting. Actually the first panel I ever had holes put in for a front rack (on my orange Buddy) was done by the dealer. When I had the accident on my orange Buddy and they said my scooter was totalled, the front panel was all scratched up so I ordered a new one.

I just duplicated where the dealer had placed the holes to mount the rack (so I now had a new front panel piece) and the picture you see is basically how the dealer had drilled the holes on the other one.

Unfortunately, as the holes on my front panel are where they are now, it is physically impossible for me to test your theory.

Perhaps others will comment on whether the holes on their panel line up.

I did note in my disclaimer that I'm not a professional...