Resurrection vs. Restoration


This ad disappears when logged in

TR6SC

Wore out three sets of tires already!
Jun 12, 2016
965
2,358
66
Eureka, CA
#1
image.jpeg
I'm starting to think my new/old Wingbar is like an adopted pound puppy. A good dog that's been abused. It was purchased sight unseen from a non-bike person. Questions having to do with condition fell upon deaf ears. So the pooch is mine, and that's that!
Problem #1 was addressed today. The rear axle/chain adjusters were broken many years ago. Someone tried to drill them out. As Alex would say, "Real Horrorshow!" I've got a buddy with an EDM. Electrical Discharge Machine. You put in the electrode that is appropriatlely sized and it eats through whatever is in its way. Now that the steel is gone, I can arc in some aluminum and go about the process of getting some threads in place.
This bike will never see all the bells and whistles that some have, but it is certainly worth a trip to the vet!
image.jpeg
 

TR6SC

Wore out three sets of tires already!
Jun 12, 2016
965
2,358
66
Eureka, CA
#3
Here's the Beast. The frozen broken axle adjusters are only the start.
image.jpeg

The seatpost will not come out. Neither secret sauce nor heat has helped. The pipe wrench and the vise only mangle metal. Like I said earlier, somebody beat on the brat with a baseball bat!
image.jpeg
I've chosen to drill. Having only bits up to 1/2", I haven't completed the job. Working gradually, 1/16" at a time, I'm staying centered in the post.
image.jpeg
I'll finish later this week at a friend's well stocked shop. Sad to say, this slotted sex-bolt was also frozen beyond salvation. It's going to be work, work, work...

image.jpeg


image.jpeg

New key!
image.jpeg


image.jpeg


image.jpeg


image.jpeg

image.jpeg
I was able to find a lady's fork that I'm going to spin in the lathe for the 1"-24tpi that it needs further down the stem.

image.jpeg
 
Last edited:

TR6SC

Wore out three sets of tires already!
Jun 12, 2016
965
2,358
66
Eureka, CA
#5
Finally got to the seatpost on the Wingbar. My theory was to work up through the drill sizes to always stay centered in the seatpost. The blue tape was the depth of the post, so I didn't want to get off centered. The frame is only 1/16 thick.
image.jpeg

Problem number 2 is that long drill bits are pricey and there is no such animal as an extension. A buddy has a lathe, so I made one.
image.jpeg

I was able to follow the inside hole of the seatpost while stepping up 1/16 at a time. I drilled all the metal except the bottom angled portion of the post
image.jpeg

I want to clean up the top of the seat post. Will one of the experts post a photo showing what that area looks like? Thanks. And, what is the little hole on the casting for? Thanks. Finally, what's the diameter of the seat post? Thanks again.
 
Last edited:

TR6SC

Wore out three sets of tires already!
Jun 12, 2016
965
2,358
66
Eureka, CA
#7
Now that the kinks and twists are out of the bike, I'm going after the other aspects of the damage to the frame.
image.jpeg

Not only were there dings and scratches, the inner surfaces were riddled with casting marks that were never detailed in 1936. Hmmm, imagine that!
image.jpeg

These craters need to be filled in order to save the Serial #s.
image.jpeg

More heavy filing to smoooooth.
image.jpeg

The broken adjusters and the broken drill bits are now gone. These areas will be filled with molten lava or aluminum, whichever is available. I'll drill and tap through solid metal.
image.jpeg

What a mess. These axle slots will get squeezed to 3/8" and more filling and filing to tidy up the rear end.
image.jpeg

I'm looking forward to going at this bike with some fine grit sandpaper, at least #1500.
 

TR6SC

Wore out three sets of tires already!
Jun 12, 2016
965
2,358
66
Eureka, CA
#10
Baby Steps! After filling the cut out drop-outs, I did some rough shaping to get things into shape, and finally drill and tap.
image.jpeg

image.jpeg

#3 drill bit (0.213") leaves just the right amount of metal to cut the 1/4-28 threads. The rear end is now ready to grind and sand to #220.
image.jpeg

Once all areas of the Wingbar look like this, I will decide how polished it's going to be. I'm starting to think along the lines of #600, followed up by Scotchbrite.
image.jpeg


image.jpeg


image.jpeg
 

Talewinds

I live for the CABE
Sep 13, 2010
1,897
172
Newton, WI, United States
#11
You're doing some terrific work on that frame, it's worth saving! If you sand it to 600, might as well keep going. I had to start with a file on some spots on mine, then work my way up to 2000, finishing with Maas metal polish. I say it like it's no big deal, then again, I'm still procrastinating doing my handle bars and speedo stem because the memory of doing the frame must not be far enough out of my mind yet...
 

Kickstand3

Wore out three sets of tires already!
May 16, 2014
695
985
Grapevine Tx
#14
Likes: TR6SC

TR6SC

Wore out three sets of tires already!
Jun 12, 2016
965
2,358
66
Eureka, CA
#18
Wow, I really admire your welding skills and craftsmanship. Yeah there's other players in the court but most of them use computerized machinery and digital equipment. Very few use their hands and manual skills to perform complicated tasks. Great job, congratulations!
Too kind. Not all my craft. Like many of us out there, I find the talent that I'm short on or that is better than mine. I do what I'm good at, and invite those with more skill or tooling to help with improving the end result. My strong points are enthusiasm and endurance.
 

TR6SC

Wore out three sets of tires already!
Jun 12, 2016
965
2,358
66
Eureka, CA
#19
This was the last nightmare to tackle. The set-screw that holds the lock was removed over 6 months ago. I've soaked, heated, twisted, and almost even pounded on to no avail. This lock won't budge. I've rebuilt the one in the Flo-Cycle, so I have an understanding of what I'm up against to some degree. I came to believe it needed a push from behind, and I decided to drill just off center of top and bottom of the cylinder from the other side of the frame.
image.jpeg

It was only going to be two holes, but when tap tap tapping didn't feel right, well...
image.jpeg
Looks ugly. I'm almost ashamed but the hammering needed to happen at the edge of the lock to keep from damaging it.
image.jpeg

Here's where the drill bit hit the lock. The one at 6 o'clock was the the one I wanted. Pop goes the weasel. Out it came.
The rest of the process is about making the key. Drilling out the stepped cam gains access to the guts of the matter.
image.jpeg
image.jpeg
image.jpeg

image.jpeg

The ten wafers must be flush with outside of the inner cylinder. Any protruding wafers will be caught in the groove, keeping the lock locked. Making of the key is in another thread posted in The Workshop-Oct 20.
image.jpeg


image.jpeg


image.jpeg
 

NoControl

Look Ma, No Hands!
Oct 11, 2017
65
76
60
Bennington, NH, United States
#20
Thanks. Hopefully this sort of abuse won't happen again. I'm thinking of installing some Heli-coils to assist in no frozen threads in the future.
I'm admiring your old-timey repair skills.

Growing up in my father's machine shop, I watched him do repairs like this hundreds of times. We lived on the coast of Maine, so his work was mostly for marine applications. I've seen him do some miraculous repairs to cast iron, cast aluminum, cast bronze, and zinc. After I got out of the USAF, I used the skills he taught me to repair obsolete printing presses and other manufacturing machines that were abandoned by their original manufacturers. How do you buy a replacement widget for a thingamabob, when they no longer exist? You can't! You make one!

Kudos to you, TR6SC. Beautiful work you are doing, and what a prize you'll have when complete!
 

This ad disappears when logged in
Most Recent BUY IT NOW Items Listed on eBay
$6.60
eBay Auction Picture
$20.00
eBay Auction Picture
$6.60
eBay Auction Picture
$39.95
eBay Auction Picture
$43.00
eBay Auction Picture
$47.00
eBay Auction Picture
$49.00
eBay Auction Picture
$125.00
eBay Auction Picture
$86.00
eBay Auction Picture
$7.99
eBay Auction Picture
$34.00
eBay Auction Picture
$27.95
eBay Auction Picture
$68.00
eBay Auction Picture
$58.00
eBay Auction Picture
$40.00
eBay Auction Picture
$88.00
eBay Auction Picture
$45.00
eBay Auction Picture
$0.00
eBay Auction Picture