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# Tech Design Works

The intersection of craftsmanship, design & technology

## Sitemaps

- [XML Sitemap](https://techdesignworks.com/sitemap.xml): Contains all public & indexable URLs for this website.

## Posts

- [Blog](https://techdesignworks.com/blog/) - TEST- this will appear at the top of each page
- [Three Years with a Heinkel EV](https://techdesignworks.com/2026/02/three-years-with-a-heinkel-ev/) - Three years ago I wrote an article about my Heinkel Kabine EV conversion. I’d like to give an update about what has gone well, what has not, and what I would do differently if I were to convert another car today. Converting my Kabine to an EV has been the best improvement I’ve made to
- [LED Headlight](https://techdesignworks.com/2026/02/led-headlight/) - A Heinkel friend of mine was installing an LED headlight in his Heinkel Tourist scooter so that got me thinking. I needed another reflector for the Bella R204 restoration that I was completing, which would cost 37 euros plus shipping from Germany. Instead, I bought a DOT and SAE approved LED light and converted it
- [A Little Trailer for My Little Car](https://techdesignworks.com/2025/11/a-little-trailer-for-my-little-car/) - I built my Campi-style trailer during Covid to attach to my Heinkel Tourist scooter. I like towing it much better with my car. It's perfect for quick trips to the beach or hardware store.
- [So Many Wires!](https://techdesignworks.com/2025/06/so-many-wires/) - I've started the EV low voltage wiring. There are so many more wires than a stock Bella R203. I've designed a new wiring loom to accommodate turn signal wiring, brake light wiring, kill switch, and DNR switch. None of these were on the original bike.
- [The Bella EV Scooter is Done!](https://techdesignworks.com/2025/11/the-bella-ev-scooter-is-done/) - I finished the Bella EV conversion in August and have been putting it through a series of shakedown rides to tighten up loose things and make sure everything performs as expected. The results of the conversion have exceeded my expectations. It accelerates quickly and I’ve gone 50 mph, with an estimated top speed of 68
- [Centerstand Repair](https://techdesignworks.com/2025/05/centerstand-repair/) - Centerstands take a lot of abuse on every kind of scooter. I've restored Vespas, Lambrettas, Heinkels and now a Bella, and every one of them required repair. The ones for my Bellas were particularly bad, one of them so much that I was afraid the scooter would stay upright once I installed my big battery.
- [Paint Saving Plastic Spacer](https://techdesignworks.com/2025/05/paint-saving-plastic-spacer/) - I'm not a fan of the way the bodywork is attached to the Bella frame. In fact, the legshield isn't technically attached at all! It's only through the legshield connection to the floorboards, which are attached to rods that thread through pieces that are then secured to the frame is everything secured. This leads to
- [How Do You Chose Paint and Upholstery?](https://techdesignworks.com/2025/05/paint-and-upholstery/) - I wanted a blue car. I saw a great photo in an old Heinkel Club calendar of an elderly couple next to their car and I thought "that's the color I want". I used single stage paint to maintain the original color depth. The fabric supplier I found at a holiday craft fair. She made
- [EV Frame Components and Swingarm Parts Fabrication](https://techdesignworks.com/2024/12/ev-frame-components-and-swingarm-parts-fabrication/) - Now it’s time to see some real stuff! When I put it together it looks like this: The big wooden box is my battery doppelganger - the real one weighs over eighty pounds and isn’t exactly easy to move around. The welded swingarm looks like this: I used PTFE-coated sleeve bearings to hold a 14mm
- [Heinkel Cars and Cabin Scooters Blog](https://techdesignworks.com/2021/12/heinkel-cars-and-cabin-scooters/) - In 2011 I purchased two Heinkel project vehicles and set about restoring them. I learned a lot in the process and kept a blog to keep track of what I did and help other people who were restoring vehicles. I've been expanding my horizons ever since and I've incorporated my standalone blog into TechDesignWorks. I've
- [If Scooters Could Talk](https://techdesignworks.com/2023/09/if-scooters-could-talk/) - I was looking for a Heinkel Scooter to convert to an EV and I ended up with TWO Bellas! I'm happy though- and they will be too when they are done.
- [Animated Wooden Dinosaurs](https://techdesignworks.com/2025/01/animated-wooden-dinosaurs/) - I stopped doing scooter projects at the end of October so I could concentrate on making Christmas gifts. This year I made animated wooden dinosaurs for my Granddaughter's first birthday. Here’s some pictures and a link to google with some videos of them. They are based on designed by Dave Wakefield in his book Animated
- [Why EV Batteries are Special](https://techdesignworks.com/2022/09/why-ev-batteries-are-special/) - An EV battery isn’t like a typical car battery. It's probably the most important part of the whole EV conversion.
- [I'm Getting That Wired Feeling!](https://techdesignworks.com/2022/09/im-getting-that-wired-feeling/) - I'm almost there- I hope to get my safety inspection and plates this week. Here's a picture I took today with some explanatory comments:
- [Epoxy Wooden Coasters](https://techdesignworks.com/2025/01/epoxy-wooden-coasters/) - Since Covid we've had a family tradition of making instead of buying gifts. This is an exciting time, especially since I have a talented family! This year I made drink coasters of mostly scrap wood and tinted epoxy. These look simple but were deceptively complex to make. I also needed to make storage boxes which
- [Blasting and Painting](https://techdesignworks.com/2024/04/blasting-and-painting/) - I've spent the last few weeks on abrasive blasting and painting. Abrasive blasting using crushed glass for alloy parts and coal slag for steel will remove all rust and corrosion.
- [Zundapp Bella EV Components](https://techdesignworks.com/2024/07/zundapp-bella-ev-components/) - I finalized the powertrain design, and purchased and received the major EV components. With my design and component selection I should be able to achieve my riding goals: Ride at speeds between 35-50mph (55-80kph) for sixty miles (100km). all of Have good acceleration from traffic lights and stop signs. Maintain or slightly exceed posted speeds
- [EV High Voltage Wiring](https://techdesignworks.com/2025/04/ev-high-voltage-wiring/) - Before I forget- did you know that you could electrocute yourself by working on an EV and not following the proper safety measures? If you are unsure, don't try to work on an EV conversion. And now back to our regularly scheduled programming... EV’s have two types of wiring; high voltage and low voltage. High
- [AI-Generated Art for a Scooter Rally Sticker](https://techdesignworks.com/2023/09/ai-generated-art-for-a-scooter-rally-sticker/) - For the 2023 Heinkelfest one of the attendees added a twist: bring a sticker from your hometown to trade with the other attendees. It's a familiar tradition in other parts of the world but not common in Beverly. Beverly isn't a tourist mecca worthy of stickers (except for a seal named Shoebert that spent time
- [Metal for Swingarm](https://techdesignworks.com/2024/05/metal-for-swingarm/) - I found scrap aluminum 6061 plate that will be perfect for CNC'ing the swingarm components. Here's a preliminary CAD design:
- [Bella EV Motor and Parts Unboxing](https://techdesignworks.com/2024/05/bella-ev-motor-and-parts-unboxing/) - I got my parts from QS Motor. Thirty days by ship isn't a long time and is only 60% of the cost of air freight. Let's see what I got: Once I receive the battery I will make the mounting components on my CNC.
- [Designing the Swingarm and Battery Holder](https://techdesignworks.com/2024/05/designing-the-swingarm-and-battery-holder/) - There aren't any conversion kits for Bellas, so this is where the real fun begins; designing! The result of this step is learning the actual size of the engine, wheels and battery storage of your EV conversion. The first step is to measure. If you've read other parts of TechDesginWorks you know I started as
- [Amperage Requirements of a Zundapp Bella Conversion](https://techdesignworks.com/2024/05/amperage-requirements-of-a-zundapp-bella-conversion/) - This will be a 72 volt conversion, which means I'll need to step down the voltage to 12 volts to avoid blowing the light bulbs. The stepdown is done with a DC-DC converter, which will reduce the voltage from the pack to something the original (actually rebuilt) wiring harness can handle. Converters come in different
- [ICE vs. EV Drivetrain Weights](https://techdesignworks.com/2024/05/ice-vs-ev-drivetrain-weights/) - I've done the math to determine the weight differences between the internal combustion engine ("ICE") and EV drivetrains. There really isn't much of a difference.
- [Why Convert a Bella (vs. something else)?](https://techdesignworks.com/2024/05/why-convert-a-bella-vs-something-else/) - I’ve owned Vespas, Lambrettas, Heinkels, Hondas, and now Bellas. I’m going to let you in on something I’ve discovered: Bellas might be the best candidates for conversions of any two wheeled vehicles! Why is that? There’s a strong interest in them around the world so there’s an appreciation of the design plus parts availability. There’s
- [Zundapp Bella R204 Brochure (French)](https://techdesignworks.com/2023/09/zundapp-bella-r204-brochure-french/) - This brochure came with my Zundapp Bella R204. have you ever seen it before?
- [Vespa 8" Disk Brake](https://techdesignworks.com/2023/06/vespa-8-disk-brake/) - Installation of an 8" disk brake on a vintage Vespa scooter
- [Vespa Re-Restoration](https://techdesignworks.com/2023/02/vespa-re-restoration/) - When it comes to two wheels it's not "all Heinkel, all the time" at TDW! I got my start in scooters with a 1964 Vespa, and recently I rehabilitated my first scooter after it fell into the clutches of Peromyscus leucopus: What could be so bad about a scooter becoming a mouse hotel? Mice and
- [Heinkel Kabine EV Conversion](https://techdesignworks.com/2022/05/heinkel-ev-conversion/) - I converted one of my cars to EV! If Ernst Heinkel had a viable electric option when he conceived the Kabine he would have chosen it. A modern electric powertrain is perfect for a 600 pound microcar designed for short trips and low cost operations. Instead he chose a scooter engine and the rest, as
- [Heinkel Rear Shock Bushing Replacement](https://techdesignworks.com/2024/01/heinkel-rear-shock-bushing-replacement/) - Heinkel Cars and Scooters used the same rear shock, which was quite convenient for the factory since the engines used in both vehicles were virtually identical. The shocks were made by Boge and Boge-specific parts are not available. However, with a little hunting around you can find some substitute parts. If the shock is leaking
- [CNC Laser Boxes](https://techdesignworks.com/2024/01/cnc-laser-boxes/) - A logical extension of your CNC repertoire is laser cutting and engraving. My Sienci CNC has a 7 Watt diode option which you can read about here. Why would you use a laser? For me the answer was obvious; because it existed... Capabilities of a Diode Laser There isn't a "one size fits all" laser
- [Initial Assessment](https://techdesignworks.com/2023/07/initial-assessment/) - Buying a scooter sight unseen means you get surprises. Pictures are good but don't always make you aware of what you're getting into, even when they show you obvious issues or things you should be really happy about. That's the case with this Heinkel. The goal of the initial assessment is to highlight problem areas
- [The Worst Restoration Task?](https://techdesignworks.com/2023/07/the-worst-restoration-task/) - What do you think of when you hear the word “Restoration” applied to a vehicle project? Your answer may be different than mine, and that’s probably why some auction sites prohibit the use of the word. For me “restore” means complete disassembly, repair, component renovation/replacement, reinstallation and testing. What’s the worst restoration job? Cleaning! It
- [Emergency Brake Improvement](https://techdesignworks.com/2023/06/emergency-brake-improvement/) - I installed a disk brake on the rear wheel as an emergency and parking brake. Because it's hydraulic I couldn't use the original Heinkel ratcheting lever, so I installed a motorcycle lever style activator. This presented another problem; how to keep the brake engaged while parking. Here's the solution: Here it is in place: And
- [1960 Heinkel 103-A1](https://techdesignworks.com/2022/11/1960-heinkel-103-a1/) - Mike McWilliams (Heinkeltourist.com) told me about this scooter in Connecticut. It was about to lose it's home so who better to rescue it than me? I restored the scooter as a Covid project and later sold it on Bring a Trailer:
- [1958 Heinkel 103-A1](https://techdesignworks.com/2022/10/1958-heinkel-103-a1/) - Mike McWilliams (Heinkeltourist.com) also told me about this scooter in Idaho. The most appealing attributes of this scooter were the original paint and that it was stored in a dry climate, which reduced the amount of rust, I restored the scooter in 2017 and later sold it on Bring a Trailer:
- [Lambretta Li 150](https://techdesignworks.com/2023/02/lambretta-li-150/) - This scooter was the start (and end!) of my 2 stoke tuning obsession. The stock 150 is pokey at best, so I thought I'd add some zip with tuning products that were just coming available in the early 2000's. Here's what I did: Engine Deanspeed 185 kit New Seals and Bearings New clutch and clutch
- [1962 Heinkel 103-A2](https://techdesignworks.com/2023/04/1962-heinkel-103-a2/) - I found this scooter on eBay, a guy in New York wanted to sell and said he would include delivery as part of the sale. How great is that? Delivery day also happened to be shopping day, but the seller said he wouldn't be there until the afternoon so we felt fine leaving the kids
- [Vespa Engine Tuning](https://techdesignworks.com/2023/06/vespa-engine-tuning/) - Once the engine is out of your scooter you've opened a Pandora's Box of potential maintenance and upgrade projects
- [Vespa Bodywork](https://techdesignworks.com/2023/02/vespa-bodywork/) - Patching and Painting a unibody Vespa requires special considerations
- [Is a Heinkel EV Heavy?](https://techdesignworks.com/2022/12/is-a-heinkel-ev-heavy/) - An EV drivetrain is heavier- but not as much as you thought
- [Packing Battery Heat](https://techdesignworks.com/2023/03/packing-battery-heat/) - If you have an EV and live in a cold climate you know the effect that winter weather can have on your vehicle's range. In my case the Heinkel absolutely would not run below 50 degrees F (10C). There were telltale signs that something was amiss with my BMS too- one of the boards would
- [Would the Postal Service be Proud?        ](https://techdesignworks.com/2023/02/would-the-postal-service-be-proud/) - I was looking for an alterative to fish paper for wrapping my LiFePo4 cells before reinserting them into my battery case. Why wrap cells? To keep them physically separate and prevent any errant electrical connections. The usual wrap is something called Fish Paper, which doesn’t have much to do with fish (as far as I
- [Restore Your Heinkel ( or Any Car!) Wiring Harness](https://techdesignworks.com/2015/02/wiring-harness-restoration/) - Heinkel Kabine Unrestored Wiring Loom Five decades of wear, tear and storage have taken their toll on your wiring harness. You may not be aware of what damage lurks behind the frayed covering or over-sprayed paint on your car’s wires. If you are restoring your car, or just want to have reliable service, you'll need
- [Make Your Own Heinkel Engine Cooling Tins](https://techdesignworks.com/2015/06/a-microcar-in-microcosm/) - My summer project is to rehabilitate the body of my second Heinkel car. This will be no small task since the car needs floors, sills, wheel arches, door tube, louvers, roof rails, and a gas tank supporting panel. In other words, it needs a lot of work. My second Heinkel Car To outsource this kind
- [We Have a Winner! Misselwood 2015 Concours](https://techdesignworks.com/2015/07/we-have-a-winner/) - I entered the Misselwood Concours d’Elegance in my hometown of Beverly, MA. It is one of two concours held in the New England area (the other is in Greenwich, CT). I won second place in the 1960-1969 category! Getting an award for the Heinkel Kabine I was quite excited. Of course I’m a little biased
- [Colorado HeinkelFest 2015](https://techdesignworks.com/2015/10/colorado-heinkelfest-2015/) - I attended the Colorado HeinkelFest in Colorado Springs in last month. I’ve attended 3 out of 4 modern-era HeinkelFests, which are wonderfully organized on a biennial basis by Mike McWilliams of HeinkelTourist.com. At the Summit with my Heinkel Scooter You can read all about the 2013 event here on my blog:https://techdesignworks.com/?p=514. The 2015 edition had
- [No Sunroof For You - A Metal-Roofed Heinkel!](https://techdesignworks.com/2016/04/metal-roofed-heinkel/) - There’s a rarity among rarities listed on German eBay right now- a Heinkel with an all metal roof. No sunroof for you- a most unusual Heinkel This is the second one I’ve ever seen. I thought the first one was some sort of early prototype. This one appears to be from the very end of
- [Jetex Carburetor Conversion- Better Than an Old Pallas](https://techdesignworks.com/2016/05/jetex-carburetor-conversion/) - If you’ve read my blog you know that many Heinkels suffer from carburetor problems. Parts are no longer available for the original Pallas carburetors. The slides wear or they leak gas (and air), resulting in poor idle and a host of other issues. Even if you manage to get another Pallas carb, chances are it
- [The Best Carburetor Option Yet?](https://techdesignworks.com/2019/08/the-best-carburetor-option-yet/) - If you’ve read my blog over the years you know how fickle carburetors can be. I’ve tried several options; rebuilding existing ones, buying lightly used ones, buying a new Bing, using a Jetex- you name it I have tried it. In the spirit of trying to get my car to be the best it can
- [Who would have thought- a Heinkel disk brake!](https://techdesignworks.com/2022/05/disk-brake/) - I've adapted a Heinkel disk brake to the Heinkel Kabine EV build. I'll use it as a parking brake to start. If it performs well I will design a way to attach it to the now unused clutch pedal.
- [Midwest Microcar Museum - A Must See in Madison!](https://techdesignworks.com/2016/05/midwest-microcar-museum/) - There’s a number of microcar collections in the United States, which is surprising if you stop and think that many of the cars you see there were never officially imported into the country. Anytime I’m anywhere close to one I always try to visit. The hosts are invariably fascinating and welcoming. Over the weekend I
- [Heinkel Restorations- Scooters vs. Cars](https://techdesignworks.com/2012/11/heinkel-restorations-scooters-vs-cars/) - Scooters vs. Cars- How Hard to Restore?There have been a few Heinkel car projects on eBay recently, and several people have asked me how hard it is to restore a microcar compared to a scooter or motorcycle. I decided to restore a Heinkel car because I’d had a satisfying experience restoring my Heinkel Tourist scooter.
- [Heinkel Kabine Front Shock Absorber Rebuild](https://techdesignworks.com/2015/12/front-shock-absorber-rebuild/) - Heinkel Shock/Damper New shocks are not available (UPDATE: since I wrote this, the German club started stalking them), and your existing ones are probably leaking oil. Sound familiar? Just like everything else on your car you have another project on your hands. This one is a little messy but the payoff in ride comfort and
- [Heinkel Upholstery Revisited](https://techdesignworks.com/2013/09/heinkel-upholstery-revisited/) - A few people have asked me about seat upholstery. It's one of the most notable and admired features of the car. I'm no expert on upholstery- that's my wife Ann! In order to help you upholster your seats I've provided measurements, sources and hints from her which will help you to complete the job. You
- [Heinkel Seats- Part 1: Frame and Underlayment](https://techdesignworks.com/2013/02/heinkel-seats-part-1-frame-and-underlayment/) - Seats and Upholstery are another area that define the look of the car. Heinkel Car Interior Heinkels were economy cars and you’ll realize that after riding a few miles on the original seats. “Basic” is the word that comes to mind. They were originally covered with a plaid fabric facing and vinyl sides and back.
- [Heinkel Seats- Part 2: Re-Upholstery](https://techdesignworks.com/2013/02/heinkel-seats-part-2-re-upholstery/) - Nothing is impossible on a Heinkel car; it’s really just a question of time and money. If you picture the seats as their own mini project, and are willing to learn and take some time, you can get the results you want. What I learned was that it was best to outsource my seat covering
- [Steering Wheels](https://techdesignworks.com/2013/03/steering-wheels/) - When I purchased my car I received a number of steering wheels- 4 to be exact. It was hard to tell which ones were more “authentic” since all the photos I saw on the internet showed wide use of both kinds on Heinkel cars.Heinkel Steering Wheels in Various ConditionsI decided that I would use the
- [Driving a Heinkel](https://techdesignworks.com/2013/06/driving-a-heinkel/) - Now that we’re back in driving season I thought I’d write about what it is like to drive a three-wheeled Heinkel. I've made a video too! A Heinkel is not like a modern car, which can be the source of both frustration and enjoyment. Here’s a few examples: Shifting: A Heinkel standard transmission
- [My Introduction to Welding](https://techdesignworks.com/2013/04/my-introduction-to-welding/) - I took an autobody class in order to gain confidence for some future projects. I had a scooter that needed some paint and body work, and another Heinkel Car that was in poor shape. I had a project in mind: Take two bad doors and make one decent door for use on my project car.Let's
- [Rust Never Sleeps](https://techdesignworks.com/2013/10/rust-never-sleeps/) - Neil Young coined this slogan and while I don’t think he was a Heinkel owner, the phrase certainly applies. Any unrestored 50 year old car had rust issues. One of the attendees at HeikelFest told me about his experience using electricity to de-rust gun parts.The technique is known as electrolysis, and I was intrigued. I've
- [Presidential Microcars](https://techdesignworks.com/2013/11/presidential-microcars/) - We all know that Elvis Presley (the "King") had a Messerschmitt; did you know that a US President owned microcars? It turns out that Lyndon Banes Johnson, America’s 36th President, owned a Fiat Jolly and an Amphicar. He was both a car guy and gadget hound. Most of his cars are available for viewing at
- [Making my own CNC parts (again!)](https://techdesignworks.com/2022/05/making-my-own-cnc-parts-again/) - I needed a way to mount my Heinkel EV Conversion disk brake caliper. I roughed out a sketch in Fusion 360, made and fit several wooden prototypes, then cut out the final bracket out of 1/4" 6061 aluminum plate.
- [Tax Evader](https://techdesignworks.com/2016/05/tax-evader/) - Tax Evader I purchased a collection of Heinkel parts recently and found this gear selector indicator: Heinkel Car Gear Shift Selector Notice anything missing? It turns out that in the UK you could register a three wheeled vehicle as a motorcycle and pay less road tax. It must have been significant (or the purchasers of
- [Heinkel Birthday Card](https://techdesignworks.com/2013/11/heinkel-birthday-card/) - My daughter made a birthday card for me: Custom-made Heinkel Birthday Card It's made entirely of small cardstock pieces that she cut freehand and glued together. She was inspired by our dog Gabby, who loves riding in our car. Here's a video of her getting in: Here's a closeup detail of
- [A Heinkel Convertible](https://techdesignworks.com/2013/12/a-heinkel-convertible/) - This car appeared on German E-bay the other day: Heinkel Sports Convertible Prototype According the the Heinkel Club of the United Kingdom, two (or possibly three ) prototypes were built by Heinkel Cabin Scooters of Dundalk, Ireland. It's interesting to look at the photos. It doesn't have a "Heinkel-I" door badge or steering wheel insert.
- [A Great Way to Haul Your Bike or Scooter](https://techdesignworks.com/2013/10/a-great-way-to-haul-your-bike-or-scooter/) - The best way I've seen in a long time to haul a bike (or microcar!) This Article is © 2012-2014 Heinkel Cars, Kabines, and Cabin Scooters. All Rights Reserved.
- [HeinkelFest 2013](https://techdesignworks.com/2013/10/heinkelfest-2013/) - I returned to my scootering roots when I attended the 2013 HeinkelFest in Colorado Springs last month. Here's my article about it:10 Heinkels and an IWL Berlin in front of Pike's PeakPikes Peak embodies the history of America perhaps more than any other mountain in the United States. “Pikes Peak or Bust” was the rallying
- [A December to Dismember](https://techdesignworks.com/2013/12/a-december-to-dismember/) - It’s amazing what you discover when you tear apart enginesI couldn’t resist riffing off of the Lexus commercials we have ad nauseam in the US this time of year! In my case I’m working on engines.I've decided to restore my other Heinkel car (known charitably around here as "the rusty hulk"), which you’ll be hearing
- [Timing Advancer Restoration](https://techdesignworks.com/2013/12/timing-advancer-restoration/) - Bosch Timing Advancer for Heinkel Car EngineThis little item controls the timing advance on the Heinkel engine. I don’t know what to call it; a timing governor, and timing advancer? I’ll just call it a timing advancer for now.I had a few of these floating around for my parts engine. They were all pretty rusty
- [Points Felt](https://techdesignworks.com/2014/02/points-felt/) - I realized my points felt was totally worn through. Of course I just received an order from overseas and didn't plan on making one anytime soon.Heinkel Siba points with worn feltMy options were to wait a month for a new felt from the UK or find a different way. Felt removed from metal plateThe felt is
- [Stators and Armatures - Part 1: Routine Maintenance and Assessment](https://techdesignworks.com/2014/03/stators-and-armatures-part-1-routine-maintenance-and-assessment/) - What started as a short post about stator brush replacement has turned into a whole article about how I rebuilt my stator because of a pesky intermittent ground short. It was probably the most frustrating Heinkel project I’ve ever undertaken! Don’t worry though; I’ve written up a guide that should answer most of your questions.
- [Stators and Armatures - Part 2: Stator Repair and Disassembly](https://techdesignworks.com/2014/03/stators-and-armatures-part-2-stator-repair-and-disassembly/) - Besides electrical faults and component age you’re probably not going to find a lot of problems with your stator. After all, it sits in an almost hermetically sealed environment behind a big hunk of metal in a sheltered part of your vehicle. Rust and oil contamination are probably the other most frequent issues, unless your
- [Stators and Armatures -  Part 3: Armature Restoration](https://techdesignworks.com/2014/03/stators-and-armatures-part-3-armature-restoration/) - I’ve saved the biggest part for last- the armature. The armature is the heavy wound copper and metal hunk that mounts on the end of the crankshaft and spins around the stator, producing electricity in the process.Stators and Armatures come in pairs, and were manufactured by two suppliers; Siba and Bosch. They do the same
- [Make Your Own Heinkel Engine Test Rig](https://techdesignworks.com/2014/05/make-your-own-heinkel-engine-test-rig/) - I rebuilt several engines over the winter and wanted to test them before I installed them in vehicles. I’ve confidently tried just putting an engine in a vehicle, thinking it would work flawlessly, but of course after spending an hour installing it I found it needed to come out to fix a leak and an
- [Heinkel Brake System Part 5- Adjustments](https://techdesignworks.com/2014/10/heinkel-brake-system-part-5-adjustments/) - Adjustments are the final step in having better brakes. We’ll start with bleeding the brakes and wrap up with adjustments.If you've installed a new master cylinder or wheel cylinders you’ll have to bleed out the air that is now in the system. As I mentioned in a previous post, air in the system leads to
- [Heinkel Brake System Part 4- Reassembly](https://techdesignworks.com/2014/09/heinkel-brake-system-part-4-reassembly/) - Now that you've inspected and rebuilt items as needed, it’s time to put your Heinkel / Trojan brakes back together. This part is easy, especially if you work slowly and methodically.Heinkel Master Cylinders and DOT3 FluidLet’s go through the components:Master CylinderWheel Cylinders (2)Brake Shoes (2 each wheel)Brake Shoe Springs (2 each wheel, one big and
- [Heinkel Brake System Part 3- The Master Cylinder](https://techdesignworks.com/2014/09/heinkel-brake-system-part-3-the-master-cylinder/) - Heinkel Kabine Master CylinderThe master cylinder is the heart of your brake system. It contains the fluid reservoir and various seals and valves that push the fluid to stop the brakes.The master cylinder has been a problem area for me. I’ve had spongy brakes, a bad seal, and a leak. Let’s take a look and
- [Heinkel Brake System- Inspecting and Testing](https://techdesignworks.com/2014/08/heinkel-brake-system-inspecting-and-testing/) - After riding in another Heinkel with excellent stopping power, and surviving a harrowing malfunction (entirely of my own doing) I decided to spend some time thoroughly inspecting and overhauling my brakes. What follows is my five-part series on how to inspect and overhaul your front brake system. · A Heinkel Master Brake Cylinder (with car parts
- [3D Printing Heinkel Parts](https://techdesignworks.com/2014/11/3d-printing-heinkel-parts/) - An Elusive Heinkel-I Steering Wheel CenterFor the longest time having a Heinkel-I without the proper “Heinkel-I” steering wheel center bothered me. Since the part wasn’t being reproduced and was rarely offered on e-Bay, I resigned myself to my fate and learned to live with this empty spot in my car. A standard “Heinkel” steering wheel
- [Make Your Own Copper Head Gaskets](https://techdesignworks.com/2014/12/make-your-own-copper-head-gaskets/) - I was faced with an engine rebuild after I had a crankshaft bearing fail at 45,000 miles. I noticed when I removed the cylinder head that I had a groove from the copper fire ring in the composite gasket that I was using. Indent is visible on exhaust (left hand) sideI didn’t want to skim the
- [Heinkel Scooter Refresh](https://techdesignworks.com/2015/07/heinkel-scooter-refresh/) - I became interested in Heinkel cars because I had a Heinkel scooter, One day I got a letter from a guy in Kansas City offering to sell me his project car for $2,500. And was it a project! But it got me thinking, and now I have 2 cars and still have my scooter.I'm going
- [Misselwood Concours 2021](https://techdesignworks.com/2021/07/misselwood-concours-2021/) - Sunday , July 18 started as a rainy day but eventually cleared enough to become a great day to attend the Concours d' Elegance. Misselwood is one of three juried Concours in New England. I entered my Heinkel Kabine in the microcar class. They also had a "woodie" class (wooden-bodied cars) for the first time
- [A Trip to the Harley Davidson Museum in Milwaukee, Wisconsin](https://techdesignworks.com/2015/12/a-trip-to-the-harley-davidson-museum-in-milwaukee-wisconsin/) - In August we visited the Harley Davidson Museum in Milwaukee. While I’m not a Harley rider I have an appreciation for most things with two wheels, and if you are like me the museum won’t disappoint you (If you are not a bike fan I’d stay clear of this place). My wife falls into the
- [Axle, Subaxle, and Stub Axle Reassembly](https://techdesignworks.com/2015/12/axle-subaxle-and-stub-axle-reassembly/) - Once you've completed the prep work it's time to reassemble.Kingpins: Let's start with kingpins. The kingpins come as a set; kingpins and a set of lower and upper bushings. You need to insert the bushings into the subaxle- the top bushing is inserted from underneath and the bottom one is inserted from the top. After
- [I’ve been busy!](https://techdesignworks.com/2018/06/ive-been-busy/) - I haven’t posted for some time but that doesn’t mean I haven’t been doing Heinkel things. Far from it! I restored a Heinkel 103 A1 scooter and I made this:I fabricated the entire side of this KabineInstalled new roof parts too!I never welded or did metal fab before thisOver 50% of the metal is newFrom
- [The Heinkel Engine "Hall of Shame"](https://techdesignworks.com/2018/08/the-heinkel-engine-hall-of-shame/) - Over 13 years of Heinkel ownership I've accumulated a number of engines; people have given then to me, I've found them in various places, or people have told me about them and I purchased them. There are a surprising number of engines out there in the USA, especially considering that maybe only a few hundred total
- [EV Conversion Speedometer Project](https://techdesignworks.com/2022/10/ev-conversion-speedometer-project/) - Now we're in unchartered territory. The original Heinkel speedometer looked like this: Remember that Heinkels were economy cars, the speedometer only recorded the bare minimum- speed and miles traveled, But if you paid extra you could get a real (or a fake) clock! The speedometer measured travel by a cable from the top on the
- [Gas Cap Electrical Socket](https://techdesignworks.com/2022/05/ev-conversion-gas-cap-electrical-socket/) - Hiding the outlet in an EV conversion is not as easy as it sounds!
- [Modern Shifter for an EV](https://techdesignworks.com/2022/07/modern-shifter-for-an-ev/) - This isn't your grandparents' shifter. Plus a disk brake activator!
- [What are the Most Difficult EV Conversion Tasks?](https://techdesignworks.com/2022/08/what-are-the-most-difficult-ev-conversion-tasks/) - Every EV task is hard when you've never done them before! Some are more difficult than others though...
- [Swingarms, Backing Plates and Motor Mounts    ](https://techdesignworks.com/2022/09/swingarms-backing-plates-and-motor-mounts/) - The swingarm serves more roles than you probably think, and using the original motor mounts saves time and space.
- [EV Components Unplugged!](https://techdesignworks.com/2022/05/ev-components-unplugged/) - Lean about the major components of my EV build
- [Special Thanks to Two Heinkel EV Owners](https://techdesignworks.com/2022/09/special-thanks-to-two-heinkel-ev-owners/) - One of many drawings Marcelo Spina made to help me understand EV technology!
- [EV Heinkel Test Drives!](https://techdesignworks.com/2022/09/ev-heinkel-test-drives/) - I finished my initial configuration of the motor and controller and have been doing some test drives. The results have met my expectations- quick acceleration, whisper quiet and no exhaust smells. Check it out!
- [Old & New Heinkel Powerplants - Side by Side!](https://techdesignworks.com/2022/08/old-new-heinkel-powerplants-side-by-side/) - Here's a good comparison of the original Heinkel Kabine powerplant with my reversible EV conversion powerplant. On the left is a Heinkel Club of Germany (Heinkel-club.de) archival photo of the Heinkel engine and drivetrain. On the right is my EV conversion.
- [The Project Vehicles](https://techdesignworks.com/2012/08/the-project-vehicles/) - I purchased two cars in parts from England. They arrived at my house in April 2011. Of the two cars, one was in better shape than the other. My plan was to rebuild and assemble the first one, and then sell the second one and any leftover parts as a project to someone who was
- [EV Conversion Blog](https://techdesignworks.com/2012/08/welcome-to-heinkel-cars-and-cabin-scooters/) - I've decided to convert one of my Heinkel cars to EV Power. If Ernst Heinkel had a viable option I'm sure he would have chosen it- for a car like this it should be great. Hang on and here goes!
- [Speedometer](https://techdesignworks.com/2012/10/speedometer/) - When I "finished" my car I got an email from a Heinkel friend in England that basically said "Congratulations, now you'll probably spend as much time adjusting and debugging as you did restoring!". He's been right so far.One issue that has literally been in my face is the speedometer. It just doesn't work. When I
- [Heinkel Air Conditioning](https://techdesignworks.com/2013/06/heinkel-air-conditioning/) - On a sunny summer day riding in a Heinkel can get pretty warm. I have operable vent windows on my car, but they have a tendency to close as you drive faster. I came up with an easy solution to keep the windows open, even at top speed.Heinkel Window HolderI took a piece of wire
- [Welcome!](https://techdesignworks.com/2012/08/welcome/) - Welcome to Heinkel Cabin Scooters. This is the story of the restoration of my Heinkel Car, but with a little twist; I’ve already finished my car! I'd always wanted to do a project blog, but I wanted to finish the car even more. So, I’m going to go back through the various processes and start
- [The Project Vehicles](https://techdesignworks.com/2012/08/the-project-vehicles-2/) - I purchased two cars in parts from England. They arrived at my house in April 2011.Of the two cars, one was in better shape than the other. My plan was to rebuild and assemble the first one, and then sell the second one and any leftover parts as a project to someone who was game
- [Where to Begin?](https://techdesignworks.com/2012/08/where-to-begin/) - The first thing I needed to do was to take stock of what I had. Both cars were now in significantly worse shape than I expected. The damage most likely occurred in the local, not trans-Atlantic container shipment.I spoke to my local body shop experts (ABC AutoBody Care Plus) and got an assessment of what
- [Bodywork](https://techdesignworks.com/2012/09/bodywork/) - We took the red car to the body shop, and after a careful assessment we decided to totally strip the car. Not a decision to be taken lightly! The car had a lot of filler in places. Mike (my auto body guy) stripped it out, hammered the sheet metal back and prepared to fill it
- [Pictures for Heinkel Magazine Article](https://techdesignworks.com/2012/09/pictures-for-heinkel-magazine-article/) - I took a few photos today for an article I'm writing for the Heinkel-Trojan Club's Cruiser News. The scooter is my 1962 Heinkel 103-A2. The scooter isn't that much shorter than the car!This Article is © 2012-2014 Heinkel Cars, Kabines, and Cabin Scooters. All Rights Reserved.
- [Unpacking](https://techdesignworks.com/2012/09/unpacking/) - With my red car in the shop, I turned to unpacking the rest of the parts and making sense of everything. Both cars came packed to the gills with parts, plus I had a bulk carrier container full of heavier bits such as engines. I emptied the cars out quickly and organized the parts into
- [Heinkel Engines: Part 1](https://techdesignworks.com/2012/09/heinkel-engines-part-1/) - Rebuilt Car EngineHeinkel Engines have a number of virtues as well as drawbacks. Their greatest virtues are that parts are readily available, and that they are very durable. In fact, the engine of my Heinkel scooter started up after 30 years of sitting, even with a hole in the piston! Another virtue is that with
- [Heinkel Engines- Part 2: Disassembly](https://techdesignworks.com/2012/10/heinkel-engines-part-2-disassembly/) - Engine rebuilding is straightforward process. For me, the key thing is to be organized, take your time, and document EVERYTHING. I used to make a drawing of every major subassembly and keep them in a book (now I take pictures with my smartphone and they are automatically stored in the cloud). Sometimes it would be
- [For Octoberfest](https://techdesignworks.com/2012/10/for-octoberfest/) - This picture got me in the mood for Octoberfest:Dirndl-wearing Heinkel 103 A0 scooter riderThanks Burgess! Check out his fantastic blog about Isettas (and related items): http://bzisettas.blogspot.com/.This Article is © 2012-2014 Heinkel Cars, Kabines, and Cabin Scooters. All Rights Reserved.
- [Tools- Heinkel and Otherwise](https://techdesignworks.com/2012/10/tools-heinkel-and-otherwise/) - I neglected to mention in my last post that you need a few specialized tools in order to work efficiently on your engine and your car. There aren’t that many, and while you can make some of them yourself, you will need to buy others. It helps to know German when ordering toolsBaseline Tools:If you’ve
- [Inside the Heinkel Factory](https://techdesignworks.com/2012/10/inside-the-heinkel-factory/) - My friend Burgess (His excellent Isetta blog is here) gave me a scan of a magazine article about the Heinkel factory in Germany: Hienkel scooter with Steib SidecarCan't read German? Don't worry, I'll post a rudimentary (and hopefully accurate) translation very soon.This Article is © 2012-2014 Heinkel Cars, Kabines, and Cabin Scooters. All Rights Reserved.
- [Photos of the Heinkel Factory](https://techdesignworks.com/2012/10/photos-of-the-heinkel-factory/) - These are enlargements of the photos and translations of the captions of the article I posted earlier. The Heinkel factory was a 44,000 sf (about an acre) facility in Speyer. This is the giant 550 ton press where all of the stampings for the Kabine are made.A jig used to attach the stampings to the frameSheet
- [Heinkel Engines, Part 3: Checking and Cleaning](https://techdesignworks.com/2012/10/heinkel-engines-part-3-checking-and-cleaning/) - Time to get back to the Heinkel car and scooter engine! I’ve talked about tearing them down and the tools you should have to make your job easier. Now for two obligatory exercises- Checking and Cleaning:Checking:As I take items apart I measure and inspect them to make sure they are not excessively worn or don’t
- [Sunday Drive](https://techdesignworks.com/2012/10/sunday-drive/) - Engine rebuilding can be a dry topic. Let's go driving instead!Some Frequently Asked Questions:Q: Is it that loud?A: It's pretty loudQ: Is it that bumpy?A: Yes, at least as bumpy as the road you are onQ: Is it fun?A: YES!!!!This Article is © 2012-2014 Heinkel Cars, Kabines, and Cabin Scooters. All Rights Reserved.
- [Engines Part 4- Reassembly!](https://techdesignworks.com/2012/10/engines-part-4-reassembly/) - The Workshop Manual has step-by-step instructions for both the disassembly and reassembly of Heinkel engines and other components. The drawbacks of the manual include odd translations and phrasing that doesn't always make sense, or archaic terms (have you ever used “engine shellac”?). You still need the manual, but I suggest you supplement it with the following documents:Your
- [My Favorite Heinkel Photo](https://techdesignworks.com/2012/10/my-favorite-heinkel-photo/) - I came across this one in some old documents. It’s a classic Heinkel Kabine marketing shot. Dad is driving the car. Mom, well, she’s not sitting on anything since there’s no seat at that angle. The daughter has to be kneeling on the floor unless she’s only two feet tall. The boy, he might actually be sitting
- [Back From the Body Shop](https://techdesignworks.com/2012/10/back-from-the-body-shop/) - As you may recall from my earlier post, the car was going to be in the shop “for a few weeks”. Now it’s back; 5 ½ months later and three times more than I budgeted! But it is beautiful:I'd be surprised if it weighs 200 lbs; two people can pick it up easilyHole is for
- [Heinkel Hat](https://techdesignworks.com/2012/11/heinkel-hat/) - My wife (who is incredibly talented as well as understanding of my hobby!) made me a Heinkel hat for the winter.Heinkel Cars and Scooters drive around the hatAdmit it- you're jealous!! It is a beautiful hat made out of wool that should keep me warm during the long New England winter. I took some pictures
- [Heinkels at the Microcar Museum](https://techdesignworks.com/2012/11/heinkels-at-the-microcar-museum/) - I had an opportunity to go to the Bruce Weiner Microcar Museum in Madison, GA. (about an hour east of Atlanta) It is unofficially the largest collection of microcars anywhere. The entire collection is going to be auctioned off a piece at a time in February 2013, so this was my only chance to see the whole
- [Speedometer Revisited](https://techdesignworks.com/2012/11/speedometer-revisited/) - On October 17 I posted about my non-functioning speedometer, and determined the problem was down where the cable meets the engine:Heinkel VDO speedo I took it apart, and found that the speedometer drive was not making a good contact with the actual drive nut in the swingarm:A distance piece fits into this slot My little piece apparently never
- [Heinkel Tractor](https://techdesignworks.com/2012/11/heinkel-tractor/) - Jan from Sweden sent me photos of his tractor. Jan has a blog (http://skogsliv.wordpress.com/ ) about his farmhouse restoration. When he bought his house guess what he found in the barn? A Heinkel Tractor!Custom Made Heinkel TractorThis one of a kind tractor clearly started as a Heinkel Kabine. The body probably rusted out, and someone took
- [Tire Removal and Wheel Disassembly](https://techdesignworks.com/2012/11/tire-removal-and-wheel-disassembly/) - Old Tires-Remove Them With Power ToolsIf you have an old microcar or scooter you've probably run into this problem- the old tires are stuck to the rims and you can't get them off, and the nuts holding the wheels together are hopelessly fused together in a rusty embrace. Local service station tire breakers can't or
- [A Food Diversion](https://techdesignworks.com/2012/11/a-food-diversion/) - This isn't Heinkel related, but if you like Heinkels you'll probably appreciate this.My daughters prepared this "cookout" food for my birthday:Here's the twist: These are donuts!The top is coconut, the bun is a raised donut, the "cheese" is Boston CremeThe hot dog is a cake donutThe patty is a cut-in-half chocolate honey dip donutZiggy's Donuts
- [Front End Disassembly](https://techdesignworks.com/2012/12/front-end-disassembly/) - After the lighter fare of my last post it’s time to get back into some car projects. Let’s tear down a Heinkel Kabine front suspension! Front End (upside down)The front end of a Heinkel is the hardest part of the car to rebuild. Why? Because the front end on a Heinkel can be extremely difficult
- [Another Heinkel-Based Vehicle](https://techdesignworks.com/2012/12/another-heinkel-based-vehicle/) - I missed this one when I visited the Microcar Museum:It is a prototype of a Jurisch Motoplan. This is the only one known to exist, and is quite a vehicle. You can tell from the picture that it uses a Heinkel engine. There's more Heinkel underneath and inside:This looks like a Heinkel scooter gas tank
- [Switch Restoration](https://techdesignworks.com/2012/12/switch-restoration/) - Heinkel switches are one of a few high visibility items on the cars that are not available as reproductions. This may seem a little surprising since these Bosch switches were used on other German microcars of the period, including Goggos and Zundapps. A decent set of NOS (New Old Stock) ignition and turn signal switches
- [Top Dead Center Gauge](https://techdesignworks.com/2012/12/top-dead-center-gauge/) - In a perfect situation it's pretty easy to find Top Dead Center (or "TDC") on your engine. But how often do you have a perfect situation? Usually when I'm trying to find TDC it's hard to see inside the spark plug hole; it's too dark, the angle isn't right, or there's something else preventing me
- [Heinkel Bumpers](https://techdesignworks.com/2012/12/heinkel-bumpers/) - Chrome bumpers help complete the “look” of the Heinkel cars, so it was important to me that mine not only show well but were also mounted properly. Like many other parts of my restoration project, this was easier said than done. There are a few issues to consider with the bumpers:Repair/ rechrome or purchase new
- [The Saga of Heinkel Carbs](https://techdesignworks.com/2012/12/the-saga-of-heinkel-carbs/) - Heinkels and Trojans came equipped with carbs from two different manufacturers: Bing and Pallas. I've had some carb issues so I decided to dig in and fix them, and I learned a lot in the process that I thought would make a good blog post.New Bing Carb (left) and old Pallas CarbCarbs wear out. I
- [Heinkel Cars in America](https://techdesignworks.com/2013/01/heinkel-cars-in-america/) - The Future That Never Was; Heinkel Cars in Suburban America By the mid 1950’s over 200,000 imported cars were being sold annually in the US. Sensing a market opportunity, a number of entrepreneurs and/or manufacturers tried their hand at cracking the large American market and emulating VW’s success.It turns out that Heinkel was one of them. I’d always
- [Ignition Keys](https://techdesignworks.com/2013/01/ignition-keys/) - It’s not a good idea to lose a Heinkel ignition key because they’re difficult to replace. Even my local locksmith, who has keys to almost everything, including 50 year old scooters, couldn’t suggest a replacement. Because a key from one any car will fit another you’d think there’d be a lot around, but that is
- [Heinkel Cabin Cruiser Windows: Part 1: Plastic Window Restoration](https://techdesignworks.com/2013/01/heinkel-cabin-cruiser-windows-part-1-plastic-window-restoration/) - Heinkel Cars have 8 windows. Depending on your particular model, you’ll have either 5 or 7 windows made of plastic, and a front windshield of safety glass (there are some exceptions, if I’m not mistaken there were some early cars with all glass windows). This is the first of a multi-part series on window restoration
- [Microcar Museum Catalog](https://techdesignworks.com/2013/01/microcar-museum-catalog/) - The Bruce Weiner Microcar Musuem catalog is online. You can see it and download all 832 pages here.There's a lot of great reading and photographs as well. If you download the pdf version you can do keyword searches and find exactly what you want. It's amazing how many cars used Heinkel engines. I highly recommend it!This
- [Heinkel Cabin Cruiser Windows- Part 2- Installation](https://techdesignworks.com/2013/01/heinkel-cabin-cruiser-windows-part-2-installation/) - Assessing Window Fit-This One was Rejected!If you've never installed windows in a car, you’ll be an expert by the time you are done with your Heinkel. There are 6 windows to install by “traditional” methods, plus two quarter vent windows that swing out on a pivot (We’ll talk about those later).Let’s start with the windshield, since it’s
- [Excitement in the Stratosphere](https://techdesignworks.com/2013/02/excitement-in-the-stratosphere/) - Meteors, Asteroids, and now the Bruce Weiner Microcar Museum Auction. This has been a weekend of sky high activity! Every Heinkel vehicle beat it's estimate; four out of six by a wide margin.Here's the rundown:Trojan 200:$47,500 plus a 15% buyer's premiumThis was in the best shape of the Heinkels up for auction, and had it's
- [Taillights](https://techdesignworks.com/2013/02/taillights/) - A friend of mine in Scotland sent me a picture of his car before he disassembled it for body repair. It had some great looking taillights:Heinkel with Lucas L549 taillightsHe told me that these are Lucas L549’s which were used on many cars of the period, including MG’s, Austins, Triumphs, and Jaguars. They reminded me
- [Trim](https://techdesignworks.com/2013/03/trim/) - Heinkel cars originally had a two piece trim set running down each side of the car. As these cars aged or were restored, many of the cars lost these trim pieces, as they weren’t replaced for either aesthetic or cost reasons. I like the trim and was determined to put it back on my car.Trim
- [Some New Period Advertisements](https://techdesignworks.com/2013/03/some-new-period-advertisements/) - I've found some new period ads. Visit them on my Period Ads page!This Article is © 2012-2014 Heinkel Cars, Kabines, and Cabin Scooters. All Rights Reserved.
- [Cargo Net](https://techdesignworks.com/2013/03/cargo-net/) - Heinkel Cars have a cargo net on the right side of the interior. The net is a hand stitched macramé marvel. An often-cited statistic is that Heinkel lost money on each car they produced; it’s hardly surprising when you try to fix or re-weave the net by hand. It is a time consuming and confusing
- [Gear Shift Cables](https://techdesignworks.com/2013/04/gear-shift-cables/) - Heinkel scooters are notorious for being poor shifters; I can't tell you how many times I've missed second gear upshifting and downshifting. Are Heinkel cars any better?Well.... the answer is complicated. Generally I'd say yes, but only after you invest a lot of time adjusting.The Heinkel Car gearshift mechanism has a checkered history. The original
- [Pins and Caps](https://techdesignworks.com/2013/04/pins-and-caps/) - With an old car you're always on a search for hardware. Or at least I am! Here's a couple of pieces that I found hard to find, and some other sources for replacements.Hinge Pins:Hinge pins are hard to get. They are 8mm Clevis pins with a slot for a clip. Luckily 8mm is only .0024inches
- [Russian Microcars?](https://techdesignworks.com/2013/05/russian-microcars/) - May has been a big traveling month for me, including a few weeks in St. Petersburg, Russia. I thought I’d see some microcars there because of high gas prices and generally smaller roads like the rest of Europe. I couldn’t have been further off base. I did see one Microcar; the Smart coupe in the
- [Sunroofs](https://techdesignworks.com/2013/06/sunroofs/) - The Sunroof was Advertised as a Safety Feature!Almost every Heinkel Car ever made had a sunroof (I saw one on eBay a few years ago that didn't). The sunroof is an important part of the car; without it the car would be hot and claustrophobic. After 50 years most of these sunroofs have rotted or deteriorated
- [Suspension Pins Issue](https://techdesignworks.com/2013/06/suspension-pins-issue/) - I was investigating some excess play in my front end and made a surprising discovery. One of the pins that hold the tie rod to the axle crank was loose in the bushing.German Heinkel Club Pin (top) and Generic Pin (bottom)The pin didn't have any apparent wear, so I decided to measure it up and
- [Rear Cowl Holder](https://techdesignworks.com/2013/06/rear-cowl-holder/) - So many aspects of the Heinkel were value engineered I've lost count. One that has come back to cause trouble for me is the rear cowl support. A little arm swings up and supports one side of the cowl under the hinge. Everything is a little flimsy in this arrangement.Heinkel Rear Bonnet Support Holder- a
- [Transmission Crisis](https://techdesignworks.com/2013/07/transmission-crisis/) - For a long time I’ve been planning to attend the 18th annual Gold MicrocarClassic and drive my Heinkel 120 miles to the top of Mt. Wachusett. Unfortunately, on Tuesday morning (3 days before the event) I shifted my car into reverse and ended up going forwards. Clearly I did something that needed fixing if I
- [Microcar Classic](https://techdesignworks.com/2013/07/microcar-classic/) - I went to the Gould’s Microcar Classic on July 13. Charles Gould and his family have run the event for 18 years. This year they had 40 or 50 cars, featured a 120 mile ride to Mt. Wachusett, and ended at Microcar Day at Boston’s Museum of Transportation.Here are some photos:Homebuilt Microcar (roopod.com)Goggo 400 CoupeMesserschmitt HMV
- [Side by Side Heinkel and Isetta](https://techdesignworks.com/2013/07/side-by-side-heinkel-and-isetta/) - A lot of people confuse Heinkels with Isettas. Except that they both have front opening doors, and 10 inch wheels, they don't have a lot else in common. Here are some good pictures of a Heinkel Trojan next to a BMW Isetta, taken at the Gould Microcar Classic. You can see the differences for yourself:Isetta
- [Concours d'Elegance](https://techdesignworks.com/2013/07/concours-delegance/) - On Sunday I attended the North Shore Concours d’Elegance, which is held every summer in my hometown. The event is situated on a beautiful oceanfront estate, which serves as an elegant backdrop for the amazing cars that are on display each year. This year the event was going to feature a Microcar class. I put
- [Head Gasket](https://techdesignworks.com/2013/08/head-gasket/) - Cylinder heads take a beating on Heinkel cars and scooters. I have a rogue’s gallery of broken, beaten, and melted (yes, melted) cylinder heads floating around. I don’t even know why I save them but that’s another story.When I rebuilt my transmission a few weeks ago I had to re-use my head gasket. I knew
- [Ignition Timing](https://techdesignworks.com/2013/08/ignition-timing/) - Setting the timing in Heinkel Cars and Scooters is pretty easy. There are baseline marks for Top Dead Center ("TDC"), baseline ("slow"or "retarded") timing, and "advanced" timing molded right into the fan cover attached to the flywheel. You can set it and forget it or you can spend a little more time and try to
- [Jetson's Car vs. Heinkel Car](https://techdesignworks.com/2013/08/jetsons-car-vs-heinkel-car/) - Several people have told me that Heinkel cars look like something from the Jetsons, the animated 1960’s TV show. For those who remember the show but not the car, here are some comparison photos:Car from The Jetson's TV seriesThe "Family Economy Car"I can see the resemblance- they both allegedly hold two adults and two children,
- [One Year of Blogging](https://techdesignworks.com/2013/08/one-year-of-blogging/) - August 30 is the first anniversary of my Heinkel blog. Thanks to everyone who has read the blog, offered comments and suggestions, provided material, and passed the word. I didn’t have a lot of expectations when I started my blog; my goal was help other people as I’d been helped over the years by those
- [Cooling Fan Repair](https://techdesignworks.com/2014/02/cooling-fan-repair/) - Heinkel Engines have a fan screwed onto the armature that provides cooling across the cylinder fins on the engine. If you get something caught in the fan it is possible to break blades. A high speed spinning fan that's off balance could vibrate excessively.How do you fix a fan blade? I decided to try using
- [Dogs in Cars](https://techdesignworks.com/2014/05/dogs-in-cars/) - Our dogs like riding in the carWe have two dogs who like riding in the car- Henry on the kinderseat and Gabby on passenger side floor (you can see her head and collar through the vent window).Gabby is ready to drive a HeinkelHenry has an Instagram page- http://instagram.com/iamhenrythepup#. Apparently every dog these days needs one!
- [Heinkel Restorations in Progress](https://techdesignworks.com/2014/05/heinkel-restorations-in-progress/) - I'm aware of several restorations currently underway- 4 in the USA and 1 in Scotland. If you need some inspiration for your project look no further than right here:Heinkel Undergoing Restoration in USAHeinkel Engine Compartment- USAHeinkel back from paint shop- ScotlandHeinkel Door with Heinkel Badge- ScotlandIt will be great to see a few more cars
- [Car Selfie](https://techdesignworks.com/2014/05/car-selfie/) - This Article is © 2012-2014 Heinkel Cars, Kabines, and Cabin Scooters. All Rights Reserved.
- [Replacement Exhausts](https://techdesignworks.com/2014/06/replacement-exhausts/) - Car exhausts take a beating and it’s unlikely you’ll find a Heinkel that has an original functioning exhaust, or is not sporting a replacement. Unfortunately if you find yourself in need of an exhaust there’s a good chance you’ll have to make some modifications to the exhaust or the bracket in order to get a
- [Sad photo](https://techdesignworks.com/2014/07/sad-photo/) - Heinkel looks like a toy on a tow truckI broke down and needed a tow. I left the key in my ignition for several hours and I think I fried my ignition coil. I replaced it with a new coil and I was back on the road.I don't carry spare coils in my toolbox!This Article
- [Heinkel Brake System Part 2- Wheel Cylinder Overhaul](https://techdesignworks.com/2014/08/heinkel-brake-system-part-2-wheel-cylinder-overhaul/) - The wheel cylinders contain pistons that push the brake shoes against the wheel hub. If you are restoring your car you'll need to spend time on these. Taking apart a brake system on a car that has sat for some time can be challenge. The main problems are rust and dried up brake fluid.The wheel
- [Heinkel Dealer Sign](https://techdesignworks.com/2014/10/heinkel-dealer-sign/) - Here's a rarity:Illuminated Heinkel Dealer SignIt’s an illuminated dealer sign from a New York Heinkel Dealership. As you may know Heinkel scooters were imported into the US in the late 1950’s and early 1960’s. Their luxury pricetags meant that few were ever sold (estimates range from 150-300). This is a two sided sign that bolted
- [Heinkel Instrumentation](https://techdesignworks.com/2014/11/heinkel-instrumentation/) - One of my blog readers asked a question about what was a “correct” dashboard for a Heinkel. The answer is that no one really seems to know. I do have a bunch of photos that I’ve collected over time, so I thought it would be worthwhile to try to piece some things together.Dashboard Color: Every original
- [Argentine Vehicle Manufacturer Plate](https://techdesignworks.com/2015/03/argentine-vehicle-manufacturer-plate/) - You may not have known that Heinkels were built in Argentina. Apparently 2000 or so were built under license in the early 60's. A Heinkel in California recently sold on eBay that was originally from Argentina. The seller sent me some photos including one of the VIN plate.Heinkel Argentina Vehicle ID PlateA little different than
- [Spring Repairs](https://techdesignworks.com/2015/05/spring-repairs/) - After the worst winter everin the Boston area (As we approach Memorial Day we still have large piles in snow farms around town!) I finally got my car out of the shed. When I put it away there were a few things I wanted to do. And of course there were some surprises!Brakes: Last fall I
- [Gas Tank Rehabilitaton](https://techdesignworks.com/2015/08/gas-tank-rehabilitaton/) - Even big holes aren’t a problem if you take your timeWhen I removed the gas tank from my project car I had to evict a family of field mice. A big mouse picked up one of the babies and ran away, leaving other babies to fend for themselves. In a rare moment of kindness to
- [Heinkel Axle and Stub-Axle Prep](https://techdesignworks.com/2015/12/heinkel-axle-and-stub-axle-prep/) - Think of these components as the skeleton of your suspension system; everything on the front end is attached or inserted to these components. Chances are they will all need some rehabilitation work before you reassemble them. The Stub Axle: Cleaned and Repaired Heinkel Sub-AxlesI’m not even sure that’s what they are called; I’ve also heard
- [The Attica- Another Car with a Heinkel Engine](https://techdesignworks.com/2016/02/the-attica-another-car-with-a-heinkel-engine/) - I’ve been corresponding with a gentleman in Greece about his Attica, an almost forgotten European microcar powered by- you guessed it- a 200cc Heinkel engine. Giorgos sent me several pictures which I have listed below. The car is made of fiberglass, although the floor appears to be made of plywood. The bodywork is derived from a
- [Defroster/Heater Switch](https://techdesignworks.com/2019/03/defroster-heater-switch/) - I’m restoring an early Heinkel with the air vents in the door and I was missing the heater/de-mister switching piece. This is a hard to get item, and I’d been looking for a few years to find one. Since I’d been doing all sorts of metal work to fix my car, I thought I had

## Pages

- [Welcome!](https://techdesignworks.com/) - TechDesignWorks is Modern DIY- the intersection of craftsmanship, design & technology.
- [HDC](https://techdesignworks.com/hdc/)
- [Electric Vehicles](https://techdesignworks.com/electric-vehicles/) - I've started converting old two and three wheelers to EV's. It's a great combination of three things I like; tech, design, and work! I've received many inquiries on the site so I've started a new section on EV conversions. I hope you enjoy it. What I've Learned My Heinkel Kabine Conversion My Zundapp Bella EV
- [Wood Projects](https://techdesignworks.com/wood-projects/) - I started woodworking in earnest because we wanted a new kitchen and calculated that I could outfit a basic woodshop for the cost of premade kitchen cabinets. Plus, if I didn't hurt myself it might actually be fun! That was a long time ago and I've been at it ever since. I'm always doing something
- [Welcome!](https://techdesignworks.com/welcome/) - Are you interested in combining traditional hobbies with modern technologies? TechDesignWorks is the place for you! Click on a topic below to learn more, and subscribe to receive new posts. I promise there will always be something interesting. Heinkel Cars & Cabin Scooters Built in the 1950's and 60's , these vehicles are icons of
- [Zundapp Bella EV Project](https://techdesignworks.com/ev-classic-scooters/) - In 2022 I completed by year long conversion of a Heinkel Kabine to an EV (you can read about it at https://techdesignworks.com/heinkel-kabine-ev-conversion/). The conversion exceeded my expectations so I felt confident that I could (and should) convert a scooter. I decided to go on a mission to find a classic scooter conversion candidate. I started
- [Heinkel Cars & Scooters](https://techdesignworks.com/heinkel-cars-and-cabin-scooters-blog/) - In 2005 I purchased my first Heinkel scooter after years of riding Vespas and Lambrettas. In 2011 I purchased two Heinkel Kabine project vehicles and set about restoring them. I prefer Heinkels over other scooters, and have made great friends all over the world sharing information and riding together. I have learned a lot in
- [Heinkel Car #2!](https://techdesignworks.com/heinkel-car-2/) - From reading my blog you might remember that I have TWO Heinkel cars. The second car was in sad shape, but after almost seven years it's painted and ready to be assembled. I'll start that after I finish my Bella twin scooters. Stay Tuned! Latest Posts
- [Best Scooters for an EV Conversion](https://techdesignworks.com/conversion-candidates/) - Why are many metal-bodied vintage scooters good EV conversion candidates? Because they look great and are functionally obsolete. If you think about it for a minute… Generally speaking, vintage scooters with less than 125cc’s have slow acceleration, limited top speed, poor lighting and poor braking characteristics. That doesn’t mean you can’t ride them, but you
- [Heinkel Period Ads](https://techdesignworks.com/heinkel-period-ads/) - A few Heinkel period ads
- [Metal Bodied Vintage Scooters](https://techdesignworks.com/vintage-scooters/) - I've been riding scooters for 50 years, and working on them for almost as long. I always seem to have a scooter project in progress. Check out some of my recent restoration and modification projects below: Latest Scooter Posts
- [What I've Learned About Doing EV Conversions](https://techdesignworks.com/ev-learning/) - I started my EV journey a few years ago and have learned a lot. It hasn't always been easy to figure things out, but when I have it's felt great! And I'm still learning things... I've combined what I've learned with my experience on scooters and microcar restorations into these categories to help you on
- [EV Components and What They Do](https://techdesignworks.com/ev-components-and-what-they-do/) - These are typical major components for a microcar or scooter conversion, what they are for, and some variations you might consider: [table id=10 /]
- [Other Metal Scooter Conversions](https://techdesignworks.com/other-metal-scooter-conversions/) - People are doing very interesting conversions around the world, and not just Lambrettas and Vespas. Here's a few examples: Heinkel EV Study, 2023 I completed a mockup with detailed measurements in wood on a scooter I was restoring. The results were excellent; plenty of room for components, at least a 40ah battery (good for 35
- [Heinkel Kabine History](https://techdesignworks.com/heinkel-kabine-history/) - Heinkel Cars were a product of post-World War II industrial and political policies. Talented aircraft engineers could no longer ply their trade designing military planes, and Europe had an acute need for basic and economical transportation. Dr. Ernst Heinkel, eponymous founder of Heinkel, saw the ISO microcar and thought he could go one better. ISO
- [Starting Your EV Project](https://techdesignworks.com/starting-your-ev-project/) - Setting Goals for an EV Conversion Vintage scooters are good candidates for EV conversions. Many are sitting as static displays or slowly deteriorating in sheds and barns. EV conversions can breathe new life into these vehicles and attract a new generation of riders to the hobby. As a converter of you’ll enjoy some benefits yourself:
- [EV Conversion Costs](https://techdesignworks.com/ev-conversion-costs/) - Converting a classic metal scooter to an EV is not a turnkey operation (at least yet, although that may change in the future). Kits are available that can make the conversion easier, and they really aren’t that expensive considering the amount of work, experimentation and false starts involved with a conversion from scratch. But you
- [Bella EV's From Around the World](https://techdesignworks.com/zundapp-bella-evs/) - A great way to start your EV project is to find previous conversions and learn from their examples. There’s a cachet about being the first to do something, but it might be cheaper and easier for you to be a "fast follower". And, imitation is the highest form of flattery! I found five examples and
- [CNC Engraving](https://techdesignworks.com/cnc-engraving/) - Most people with hobbyist CNC's produce 2D and 3D carvings made of wood, and these machines can do an exceptional job with plywood or hardwood. Except for prototyping, very few of my projects have been made of wood. My first project was to engrave glass with a diamond bit! If I only knew then what
- [CNC](https://techdesignworks.com/cnc/) - While I was building my Campi-style trailer I realized that there had to be an easier way to cut complex shapes out of wood. There is; It's called a CNC machine. What's a CNC? Once only the province of machine shops, CNC (Computer Numerical Controlled) machines are becoming indispensable tools in modern woodworking shops and
- [Epoxy River Board](https://techdesignworks.com/epoxy-river-board/) - In 2016 we took a wonderful vacation to Cape Breton, Nova Scotia. It's a beautiful area with unspoiled beaches and not a lot to do but admire the scenery; think of California Highway 1 with almost no food choices. On one of our beach walks we collected a bag of beautiful beach rocks. Someday I
- [3D Cutting Boards](https://techdesignworks.com/3d-cutting-boards/) - I decided to make some handmade gifts for Christmas with the extra wood from my Charcuterie project. There were a few weeks left before Christmas, so I went into the "Bonus Round" to make a few 3D cutting boards. They look great but are by no means a weekend project! Cutting boards (as opposed to
- [About TechDesignWorks](https://techdesignworks.com/about/) - I’ve been designing, building and restoring things ever since I can remember. Now that I'm semi-retired I can spend my time learning how to use new tools and techniques to do things that I never imagined. After college I started renovating houses with my wife, and designed and built furniture for inside and outside. No
- [Heinkel Kabine EV Conversion](https://techdesignworks.com/heinkel-kabine-ev-conversion/) - July, 2022: If Ernst Heinkel had the option of electric drive when he designed the Kabine would he have chosen it? After having thought about it for a long time I decided to make my own Heinkel an EV to find out. Here’s the story of my conversion and you can decide for yourself! If
- [CNC Furniture](https://techdesignworks.com/cnc-furniture/) - The CNC Kit doesn't come with a work surface- you have to create one. My CNC machine needs a 4x4' absolutely flat surface in order to make 30" square pieces. By the time you add in the rail mounting area, computer equipment mounting and circulation space I needed about 75 square feet of space. That
- [Shutters!](https://techdesignworks.com/shutters/) - My car project was on hold due to supply constraints, so why not undertake a house project? If you have a wooden house you know there's no shortage of projects and I have just the tools to complete them. Here's a 30 year old wooden shutter; sad isn't it? I had eleven sets to make
- [Campi-Style Motorcycle Trailer](https://techdesignworks.com/campi-style-trailer/) - June, 2020: Here's something I finished during the Covid pandemic for my Heinkel Scooter: a single-wheeled trailer to tow my stuff. I had to cancel two big trips because of Covid. I'm not going anywhere this summer because of the pandemic, so I can take little picnicking, camping beer/food pickup or beach trips. It's based
- [Contact](https://techdesignworks.com/contact/)
- [Charcuterie Boards](https://techdesignworks.com/charcuterie-boards/) - Charcuterie boards are very popular and make great gifts. I decided to combine CNC shaping and hollowing techniques with a striped wood selection. For these boards I used a combination of cherry, maple, wenge, mahogany and walnut. The first step is to glue up the blanks: Then I designed the shape of the board in
- [Wedding Jenga](https://techdesignworks.com/jenga/) - Personalized Jenga is a great combination of traditional beginner woodworking with basic CNC carving. I made five different block styles using Carbide Create. Then I made a jig to hold the blocks which allowed me to have a consistent "zero" location to start the carving. Here's the CNC in action: They come out like this:
- [Privacy Policy](https://techdesignworks.com/privacy-policy/) - If you require any more information or have any questions about our privacy policy, please feel free to contact us. The privacy of our visitors is very important to us. This privacy policy document outlines the types of personal and other information is received and collected by techdesignworks.com and how it is used. Personally Identifiable Information
- [Projects](https://techdesignworks.com/projects/) - Here's a few "big" projects you might be interested in:
- [Links](https://techdesignworks.com/links/) - I am a participant in 3rd party affiliate advertising programs, where I may earn fees by linking to products and services on 3rd party sites. If disclosed on the page then these types of affiliate links are being used. I am a participant in the Amazon Services LLC Associates Program, an affiliate advertising program where
- [How-To's](https://techdesignworks.com/how-tos/)

## Categories

- [EV Conversions](https://techdesignworks.com/category/ev/) - EV conversions of microcars and metal scooters
- [How-To](https://techdesignworks.com/category/howto/) - How to DIY a task
- [CAD / CNC](https://techdesignworks.com/category/cnc/) - CAD and CNC Design
- [Gifts](https://techdesignworks.com/category/gifts/) - Gifts you can make
- [Heinkel Cars Blog](https://techdesignworks.com/category/heinkel-cars-blog/) - Archive version of Blogger’s Heinkel Kabine Blog , 2012-2021
- [Wood Projects](https://techdesignworks.com/category/wood/) - Projects using wood
- [Metal](https://techdesignworks.com/category/metal/) - Projects using metal
- [Carburetors](https://techdesignworks.com/category/carbs/) - Posts about Carburetors
- [Bodywork](https://techdesignworks.com/category/bodywork/) - Body and paint
- [Engine](https://techdesignworks.com/category/engine/) - Heinkel engine and rebuilding
- [Electrical](https://techdesignworks.com/category/electrical/) - Heinkel electrical
- [Suspension](https://techdesignworks.com/category/suspension/) - Heinkel suspension
- [Museums](https://techdesignworks.com/category/museums/) - Heinkels in Museums
- [Rallies](https://techdesignworks.com/category/rallies/) - Rallies, Henkelfests
- [Scooters](https://techdesignworks.com/category/scooters/) - Scooters
- [Brakes](https://techdesignworks.com/category/brakes/) - Brakes
- [Upholstery](https://techdesignworks.com/category/upholstery/) - Fabric, Fabric, and more Heinkel fabric!
- [Vespa](https://techdesignworks.com/category/vespa/) - Vespa VBB Rebuild
- [Bella](https://techdesignworks.com/category/scooters/bella/) - Zundapp Bella Scooters
- [Heinkel Tourist](https://techdesignworks.com/category/scooters/tourist/) - Heinkel Scooter Posts
- [Laser](https://techdesignworks.com/category/laser-for-cnc/) - Laser for CNC

## Tags

- [Heinkel EV drivetrain](https://techdesignworks.com/tag/heinkel-ev-drivetrain/)
- [8" Vespa Disk Brake](https://techdesignworks.com/tag/8-vespa-disk-brake/)
- [Vespa Restoration](https://techdesignworks.com/tag/vespa-restoration/)
- [Is there anything worse than body work? There is and you can read about it here](https://techdesignworks.com/tag/is-there-anything-worse-than-body-work-there-is-and-you-can-read-about-it-here/)