Wednesday, February 12, 2025

Vintage Bicycle Rebuild "Styles"

After rebuilding a couple of old bikes, I think each person develops a certain "style" to how they rebuild bikes. Some people prefer to modify bikes, some restore with correct or period parts, and some do only light preservation. Some people mix all three methods. Some people have a style that changes over time, based on the circumstances of each bike. 


If I had to describe my preferred style today, it would be a mixture of "practical", "correct" and "time period". The idea is to maintain the history of the bike while also making is useful in the way it was originally intended to be used. My bikes are usually comfortable, practical machines as was originally intended by the manufacturer when they were made many years ago. 



"Use original parts when possible, but if need be, replace them. The best replacement is a direct original. Second choice would be a period correct part. Third choice would be a new part that is similar to the original. Last resort is a new part that is quite different from the original."

I preserve original parts wherever possible and consistent with the safety and use of the bike. Even if an original part is worn, it should be used when doing so is still consistent with safety and function. Is there a compelling reason to remove an original part? If not, try to keep using it. Sometimes there is a safety or function reason to swap a part, but try to use originals when you can.

A direct, correct part is the best replacement when you have to replace an original. Sometimes this is possible and sometimes not. Go with a correct/direct replacement if you can.

If you can't get a correct/direct replacement, try a "period correct" part, a replacement part from the same time period. 

If a period correct part is also not available, try a newer part that matches the technology and style of the bike. For example, a new Brooks B66 saddle on a three speed bike is perfectly acceptable if the original B66 is dried or broken. Parts made of leather or rubber often degrade over time. Or for example, use a new slotted screw to replace an old slotted screw that has stripped or broken. Using a hex headed screw on a 1940 Schwinn or Raleigh would look out of place, but a new slotted screw is closer. 

 

 

"A vintage bicycle should be reasonably safe and useful. It was intended to be ridden and your project should function consistent with that intent. Don't be afraid to replace consumable parts that affect safety and ride."

I replace consumable parts that have an effect on ride and safety. I replace rubber brake blocks/pads, worn brake cables, worn/damaged cable housings, worn shifter cables, worn tires/tubes, damaged handlebar grips, etc. It's not useful to have original brake blocks that squeal and won't stop the bike, or cables that are original but snap when you need to stop quickly, or tires that frequently flat because the sidewalls blow. I suppose this would not apply to "display only" bikes in museums and the like. But for my purposes, the bike needs to work and be reasonably safe. New parts should be similar in appearance and function to the old ones, where possible.

 



"Remove grime, dirt, and rust wherever possible. Do not remove good, old paint - even if it is faded. Gently clean the old paint and decals."

 I remove rust and clean off dirt/grime. Rust is simply a chemical reaction that corrodes ferrous metals such as iron and steel. The science is fairly straightforward. Rust should not be called "patina", which is often what a salesman will try to call it ["patina" originally referred to the green-ish oxidation of copper or bronze metals, something different]. I remove rust to the extent I can do so because it is a degradation of metal and should be cleaned up. I match and patch-up paint to prevent rust from returning. I treat bare metal or damaged chrome with WD-40 and similar products to help stave off rust. 

I clean up and lightly polish old paint. Faded paint helps give the old bike its character. I gently clean and polish it, but I do not remove it or try to make it look brand new. I gently clean up old decals and leave them in place whenever possible.


"Check all mechanical parts for damage or wear. Replace broken parts, bad bearings, bad races etc. Everything should work smoothly and as-intended by the manufacturer."

The bike should work properly. Wheels should turn smoothly and run true. Steering should be smooth, reliable, and precise. Brakes should feel crisp and grab reliably (within the limitations of their engineering). A bike that looks nice may not function well if you don't clean and check all the mechanical items. 




"Add accessories that make the bike safe. Observe safety laws. Try to use accessories that capture the look of the bike but which also add an element of safety."

If you need add-on LED lights or a bag with a reflector on it to be safe interacting with traffic, do it. I like retro lights that look correct from the outside, but which contain modern LEDs inside to aid visibility. I also like LED conversions for period lights, such as LED lights for Dynohub lamps.

 



 


 

 

 


Saturday, February 8, 2025

Threading and Trimming a Bike Fork - 1941 Schwinn Henderson New World

Cutting Threads on a New World Steerer Tube

 

Late in 2024, I bought a 1941 Schwinn Henderson New World bicycle project from a bike shop in Pennsylvania. This bike was relatively complete, but the fork had been swapped for a later, post-war fork that was spray painted black. Given how unusual the "Henderson" New World variant is, I thought it would be nice to have a correct fork for this bike. 

 

1941 Schwinn Henderson New World with Incorrect Fork

The correct fork is the Schwinn-made "D" profile fork. This fork has tapered arms with a "D" shaped cross-section. This style of fork would be correct for a tourist New World from 1941 and earlier. I located a fork from a donor frame. The fork was in good shape, but the steerer tube was too long and not threaded low enough to fit this men's 21-inch frame.

The fork material is a pretty basic, soft steel. The steerer can be threaded and trimmed to a size that will fit the fork.

The first step is to have the correct tool for the job. I'm using the Hozan #426 die and handle. The correct size is 1-inch diameter by 24 threads per inch.  The die has an adjuster screw that helps set the correct depth of cut. The screw is adjust until the die fits snugly around the existing threads, but does not substantially cut those threads much deeper. The goal is to match the threads as closely as possible.

The die is mounted into the handle and is threaded onto the existing threads, turning clockwise until it reaches the end of the threads. 

 Oil is liberally applied to the cutter. Cuts are made by turning the die 1/8 or 1/4 of a turn (depending on how much resistance you meet) and then backing off (counter-clockwise) the die. You'll feel and perhaps hear the die cutting and then releasing the broken metal chips. You need to back off the die after each incremental cut in order to free the metal chips from your cutting.


The die is frequently brushed clean with an old tooth brush and re-oiled. Work slowly and carefully.

 

Notice the Oily Chips - Cut and Back Off. Also Notice Black Line.

 Every so often, the die is removed and the fork test fitted in the frame until I get the threads in the correct location all the headset parts to grab. Once that is done, the die and threads are cleaned with an old toothbrush.

Cut Threads, Down to the Mark After Test Fitting.

 

Now that the threads are cut, the fork needs to be trimmed. Again, the fork is tested fitted to the frame and I mount the headset parts. And measure the excess. In this case, I need to account for the threaded top cup (the knurled, round piece), the lock ring (the thin ring with the tooth on it), and the lock nut (the six-sided large nut on the very top). I compare what I need in terms of length to what I have. Measure twice, cut once. [In some cases, you will need to use a rectangular small file to extend the groove that the lock nut's tooth sits in. Do that before measuring if you have to do so.]

After I'm a sure of my measurement, I thread the fork into a cutting jig and cut it off with a hacksaw. 

An Old School Tube Cutter with Internal Threads 
 

After cutting, I clean all metal dust and chips from the fork and the steerer tube. I then take a Dremel tool with a fine emery drum and gently remove the cutting burr from the inside of the steerer tube. 

Once that is done, everything is test fitted again. Sometimes I don't cut enough off the first time and I need to make a second cut. If that is the case, the cutting and cleaning steps outlined above are repeated. It's better to have to make two cuts than to cut too much off...

Everything is then cleaned, greased, and assembled.

When I'm done, I have a handsome and correct fork for this New World frame, ready for polish and matching touch-up paint. 



Monday, February 3, 2025

Looking Down the Road into 2025

With the start of a new year, it is time to assess what needs to be done to properly complete projects in my workshop. It is good, at least once per year, to see how things are going and how to forge ahead into the new year.

1941 Schwinn Henderson New World: this project came from a well-known Pennsylvania bike shop that was cleaning out its old bike collection. It's a standard 21-inch men's frame, but unusual in having a Henderson-branded badge. This bike came with a post-war replacement fork and I plan to add a correct, earlier fork to the bike. Fillet brazed frame. Seller's photos below.

 





1940 Schwinn New World: this bike came as part of a parts/frames lot from a fellow collector who is well-regarded for his knowledge of Schwinn lightweights. It's another standard, 21-inch men's frame. I have the parts to build this frame up. I am considering running a set of aluminum 590mm (26 x 1 3/8) rims to broaden the choices of tires available for the bike, and to lighten the bike up a bit. It's a fillet brazed frame.


1950s Norman Invader: This is an interesting project - an unusual Norman road bike frame. The Norman brand certainly was in the US market after WWII, but it was not as large a player as Raleigh, Hercules, or Phillips. The color reminds me of my 1953 Raleigh Lenton. I have some parts for this bike, but have to still acquire a few. This frame is the old-style 22-inch "club" size. I have a 1949 Clubman in that same frame size. The Norman has Reynolds 531 main tubes.




1948 Raleigh Sports: this bike just came in - Facebook purchase. It's a nice, fairly early Raleigh in the US (Raleigh's return to the US market took place in the early 1930s - only about 15 years before this bike was made). What got my attention is how complete this bike is, how good the condition is, and the fact that it is a pre-1950 23-inch frame model.






 

Write-off: 1940 Raleigh. I bought a 1940 Raleigh Sports last year. The frame turned out to be bent in several places, including the main tubes. The top tube is noticeably bowed to one side. The rear triangle is bent. The rear triangle by itself would be fixable, but straightening the entire thing would be a challenge. It evidently suffered a strong front-end impact at some point. This project will not go forward - I'll be keeping the parts to service other bikes. 


Selling-Off? I have to reduce my collection somewhat in the coming year. I like to keep the number of bikes manageable. I keep an Excel-type chart of my collection, which includes when bikes were acquired, serviced, and my own impression of each. When the chart gets long, I tend to look at selling one or more off. The hard part is deciding which ones go...