Resurrection vs. Restoration

Discussion in 'Project Rides' started by TR6SC, Jun 26, 2017.

  1. #1 Posted Jun 26, 2017

    Wore out three sets of tires already!

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    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!
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  2. #2 Posted Jun 26, 2017

    Cruisin' on my Bluebird

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    Onward & upward, it can only get better. Looking forward to seeing how you take this.
     
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  3. #3 Posted Jul 8, 2017

    Wore out three sets of tires already!

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    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...

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    New key!
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    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.

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    #3 TR6SC, Jul 8, 2017
    Last edited: Jul 8, 2017
  4. #4 Posted Jul 12, 2017

    Wore out three sets of tires already!

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    Awesome! Watching this one, I'm sure it turn out just as amazing as the others I've seen you work on! Joe
     
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  5. #5 Posted Sep 13, 2017

    Wore out three sets of tires already!

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    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.
     
    #5 TR6SC, Sep 13, 2017
    Last edited: Sep 14, 2017
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  6. #6 Posted Sep 13, 2017

    I'm the Wiz, and nobody beats me!

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    Please keep updating with pictures.
     
  7. #7 Posted Nov 5, 2017

    Wore out three sets of tires already!

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    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.
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    What a mess. These axle slots will get squeezed to 3/8" and more filling and filing to tidy up the rear end.
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    I'm looking forward to going at this bike with some fine grit sandpaper, at least #1500.
     
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  8. #8 Posted Nov 12, 2017

    Finally riding a big boys bike

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    Your going to be the Emperor of Silver Kings!
     
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  9. #9 Posted Nov 12, 2017

    Wore out three sets of tires already!

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    That ain't gonna happen. There're already a few big boys playing the game. I'm just looking to get on the Court!
     
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  10. #10 Posted Dec 2, 2017

    Wore out three sets of tires already!

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    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
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    #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.
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  11. #11 Posted Dec 2, 2017

    I live for the CABE

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    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...
     
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  12. #12 Posted Dec 2, 2017

    Wore out three sets of tires already!

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    I hear you in regards to the easy part being the grits above #600, it's the total elimination of all flaws below #220 that give that perfect look that are killing me!! image.jpeg
    The job never ends...
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    ...and then you need sunglasses, and somebody to keep the damned thing clean. I'm getting way too old!
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  13. #13 Posted Dec 2, 2017

    I live for the CABE

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    Holy cow.....!!!
     
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  14. #14 Posted Dec 2, 2017

    Finally riding a big boys bike

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    wow nice
     
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  15. #15 Posted Dec 3, 2017

    Finally riding a big boys bike

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    Great skills and effort on your part to get this bike back in shape!
     
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  16. #16 Posted Dec 3, 2017

    Wore out three sets of tires already!

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    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.
     
    #16 TR6SC, Dec 3, 2017
    Last edited: Dec 3, 2017
  17. #17 Posted Dec 4, 2017

    Cruisin' on my Bluebird

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    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!
     
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  18. #18 Posted Dec 4, 2017

    Wore out three sets of tires already!

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    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.
     
  19. #19 Posted Dec 6, 2017

    Wore out three sets of tires already!

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    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.
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    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
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    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.
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  20. #20 Posted Dec 22, 2017

    Look Ma, No Hands!

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    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!
     
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