Magnificent! I had no idea anyone used aluminum in that era, great work polishing and I love how it turned out, congrats and well done!
They called it Durillium but it is just good old aluminum. Not sure about he metallurgy but it seems relatively soft given that it polishes quickly and easily but also scratches easily. It is easy to buff those scratches out though which is nice.
I finally got the chain lengthened and I took a maiden voyage last night. She is quiet, smooth and the steering is wonderfully stable. It is so amazingly comfortable. The gearing is pretty tall so hills can be a challenge but when you stand up to pedal this thing it is so stable you can really step on it and the big bars give alot of leverage to really mash the pedals. The Morrow coaster is more than enough to lock up the rear wheel and the drum up front modulates suprisingly well and is very progressive. The best thing about it is my wife really likes it and it fits her quite well. The Brooks saddle is by far the most comfortable saddle I have ever used and she loves how cushy it is so hopefully I can get her out on it a bit.
So here is the total cost so far:
Frame and fork: $125
Wheels: $55 dollars to build, parts were free
Re-chrome for cranks and truss rods: $70
All other parts were scavenged or free.
Total with grips and cables is around $550. By far the cheapest restro I have done and probably the best. I am just pissed because it is supposed to rain all weekend.
Given its age and aluminum construction I just hope she stays together.
1936 Wards Hawthorne Silver King
1941 Schwinn Excelsior
1993 Brave Cycles Chief
2008 Ellsworth Epiphany