Here is how I did it.
I have to preface this tutorial with the fact that I have access to a 3D printer for some of the parts I made. If you like I can provide 3D files but I cannot make more parts for your projects.
Step 1: What I Got to Start
I took the IH13 totally apart to extract
5way controller board
5way controller rubber cover
2 controller boards
and the iPod connector
Then I took the Kensington car mount and removed the MP3 player clamp off of the bendable arm by removing one small screw.
Step 2: Design the Power Regulator
I had originally wanted to have a lighter adapter for a GPS unit also but decided against it in the end (I am hoping the new iPhone will have GPS ).
Most parts were obtained at Radioshack. The LM350 variable regulator was purchased from www.digikey.com because I needed a regulator that would supply 2A or more.
Step 3: Design the Custom Parts
STL files are available here: VespaSpeakerSLT.zip
Step 4: Mod the Left Knee Pad
Using a dremel tool I cut and sanded a hole only slightly bigger than the cylindrical part of the speaker mount assembly. With a two-part epoxy I then attached the speaker mount. After that firmed up I sanded the cylindrical part flush with the front of the knee pad a filled any cracks with bondo. After sanding the bondo, some primer, black spray paint and a lacquer spray finish I had this to show for myself...
Step 5: Mod the Right Knee Pad
Step 6: Extended Cables (and Another View of Both Knee Pads)
Speaker - I used USB cable - two wires and shield ground
5way controller - I used ribbon cable (you need 6 conductors)
iPod connector - I used a VGA video cable which is shielded and has enough conductors (9) to trasmit the audio, power and control signals.
Below is another view of both knee pads.
Step 7: Remove the Vespa Glovebox
First you need access to the area behind the glove compartment. Other projects have show this before so I will go quickly through it.
1. Carefully pop off the Piaggio emblem off the front of the horn cover (I actually broke mine so I suggest you do it very carefully).
2. Remove the screw holding on the Horn cover and then remove the horn cover.
3. Remove the two screws behind the horn cover. Then open the glove box and remove three screws inside.
4. Now carefully remove the glove box panel. You will have to hold the latch down to get it past the ignition mechanism.
5. Now there is a fuse box that lives in the space behind the left knee pad. I popped that off it's mount and fed it through the opening to free the glove box panel from the rest of the scooter.
Step 8: Ground and Power
First I screwed the ground wire to the frame of the scooter. It is a bit hard to see but the black wire is screwed in behind that white box.
Then I spliced the power line together with one of the orange wire going to the fusebox mentioned earlier. The 12V lighter kit I got but didn't use had a 10A fuse inline. I would suggest you place a fuse on this line.
Step 9: Install Modified Knee Pads
Step 10: Mount the Electronics
Step 11: IPod Mount
Step 12: IPod Connector/wire
Step 13: Wire It All Up and Test
I realized that I wasn't going to be able to put everything back together because the top corner of the electronics box was going to hit the front panel. So I cut of the corner with my dremel cutter. I also covered over all openings in the box with electrical tape to keep out the dirt and grime that will probably get inside. (Sorry no pictures of the corner cut or the tape).
I also moved the fuse box and inline fuse for my speaker system near the horn so that I could have (relatively) easy access to the fuses if I needed.
Step 14: Reassamble the Vespa... and Viola!!!
The funny thing is that to hear it above the engine sound you need to crank it up pretty good. Then when you stop at a red light it sounds extra loud. I thought about adding a circuit to attenuate the volume as the speed decreases... maybe the next project.
Hope you enjoyed this project. Please post replies, I would love to hear your opinions!!!