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 Post subject: 1980's Falcon Everest
PostPosted: Tue Apr 09, 2019 11:10 pm 
Devout Dirtbag
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Joined: Sun Jul 22, 2018 5:18 pm
Posts: 138
Location: Faffing by the Sea
And so it begins...

The original plan for the falcon was to use it as a possible parts donor or cheap quick fixer upper. I even put it up for Worst Bike on RB,
then someone said that's nice! Which made me reconsider my plans.

I did a little research online which lead me back to Retrobike. Funny how that always happens. :lol:

A post titled Decent Falcon MTB from 2013 turned up this…

“The 1986/7 Bicycle Buyers Guide shows that Falcon have a range of models from the budget brand with a £140 Tri-Star, the £230 Chrome-molybdenum Everest, and the top end K2 model at £365.”

I have to confess I’ve never done a major rebuild on a bike before but I fancied having a go. I mean how hard can it be? :shock:

So far I’ve made a start by cleaning up the headset all seems to ok apart from congealed grease, bearings and surfaces are unmarked. I’ve cleaned, regressed and put it back together and cleaned and degreased the frame. I was going to repaint the frame but I’ve decided to leave alone apart from re-touching the worst parts if I can find a matching paint.


Spec found so far…

Frame - Tange 900 Cro-Mo Double butted

Headset - Tange

Rear Mech - Shimano SIS RD-TY15 (Not original)

Front Crankset - Sugino VP triple

Bottom Bracket - BSA? (feels like it’s full of gravel)

Front Wheel - Mach 1

Rear Wheel - ?

Brakes - Shimano?

Rear Tyre - Panracer Duster V-P


Attachments:
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File comment: £10 worth of bike. Wife was not impressed!
POS 1.jpg
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File comment: Before
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File comment: Stripped and cleaned
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File comment: Headset cleaned and reassembled
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File comment: Bottom Bracket
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Last edited by Oldskool13 on Mon Feb 10, 2020 9:23 pm, edited 3 times in total.
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 Post subject: Re:
PostPosted: Sat Apr 20, 2019 1:26 pm 
Devout Dirtbag
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Joined: Sun Jul 22, 2018 5:18 pm
Posts: 138
Location: Faffing by the Sea
WARNING: The following post contains scenes of Hamfisted ineptitude and may be unsuitable for viewers of a nervous disposition.

After the battle of the bottom bracket, which once removed was deemed FUBAR, a new sealed unit was ordered.

So yesterday, after performing my duty i.e. taking Mrs O S to the garden centre, I was able to get on with the Falcon.

While waiting for the new bottom bracket to arrive I thought I’d turn my attention to the rear wheel. This time I used the correct tool and the block came off fairly easily. There doesn’t seem to be any wear so it just needs a clean and lubrication.

However the wheel didn’t turn freely so I decided to check the bearings. Now, I used to have a nice dry secure garage with enough room for a car and two bikes and bench to work on. These day my bench is of the garden variety at the bottom of the garden standing on gravel. Carefully I Removed the shaft and held a container under the wheel to catch any bearings that might escape. Holding my breath the loose bearings were eased out and put in the container with degreaser, all seemed good, no pits and nice and shiney, so far so good.

Everything was cleaned and new proper grease applied and reassembled. Of course the inevitable happened. I dropped one. On gravel. :facepalm:

There was no sign of it, what to do? I still had the old bottom bracket maybe I could get a ball bearing out of that. A quick look told me it’s bigger than the wheel ones (insert expletive here). Then I saw something shining under the bench, the lost bearing! I said a silent prayer of thanks to the Gods of bicycles and cleaned it and reassembled everything. And guess what? The wheel doesn’t feel any different! Consulting my 50p boot jumble copy of Hayes Bike Book I may have overdone the grease. I’m leaving it alone for now. :oops:

The Tyre is too far gone and I don't know what make the hub is. Any ideas?


UPDATE: New bottom bracket arrived today. It took me ten minuets to fit, happy days. :mrgreen:


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 Post subject: Re:
PostPosted: Sun Apr 21, 2019 8:56 am 
Old School Grand Master
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Joined: Sun Mar 14, 2010 2:33 am
Posts: 3744
Location: Kentcestershire
What were the surfaces of the cups and/or cones like, nice and smooth, or pitted?

Also, with cup and cone style bearings, whether its wheel bearings, headset or bottom bracket bearings, you need to adjust them so that they are "just so", not too tight, which will make them not spin freely, and not too loose, so that you get play or slop in the bearing. This can be a bit of a faff and is much harder if you don't have the correct tools that allow you to hold cone part of the bearing and tighten the lock nut to it.

More info: https://www.parktool.com/blog/repair-he ... adjustment

Cup and cone hubs generally use two different sized ball bearings, with smaller ball bearings in the front hub. These are typically 20 x 3/16" for front hubs and 18 x 1/4" for rear hubs, but there are some hubs that take different sizes. You can buy loose ball bearings at some bike shops and on Ebay: https://www.ebay.co.uk/itm/Weldtite-Bik ... MXBs-WpoXw

I don't recognise the hubs, probably fairly generic and given that they have solid axles, probably not particularly high quality. Good quality cup and cone hubs from Campagnolo, SunTour and Shimano, etc. can last for ages and run really smoothly, but some of the cheaper ones just aren't as well made and will never run as smoothly, no matter how well you adjust them.


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PostPosted: Sun Apr 21, 2019 1:58 pm 
Devout Dirtbag
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Joined: Sun Jul 22, 2018 5:18 pm
Posts: 138
Location: Faffing by the Sea
Thanks for replying xerxes,

I guess I was being optimistic that a 33 year old bike would only need is a clean and reassemble. There doesn't seem to be any evidence of maintenance, althought someone tried to put a new rear mech on it because it's code is 2003.
The front wheel is Mach 1 which a french company, still going, so the back must be the same. Oddly their website says they started producing rims in 1996. The hub has JOU YL K86 stamped on it I guess that would be the year which ties in with the bike. I will have another look, it's quite possible in my inexperience I over tighten it. Once the bikes back together I'll see how it rides and maybe think about upgrades.


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 Post subject: Re:
PostPosted: Mon Apr 22, 2019 11:41 am 
Devout Dirtbag
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Joined: Sun Jul 22, 2018 5:18 pm
Posts: 138
Location: Faffing by the Sea
More work on the Falcon yesterday. As suggested I had over tightened the cones, I backed it off a hair and it's much smoother now. :facepalm:

I spent the afternoon polishing the tarnished rims and made a discovery. The rear wheel has Made in Taiwan on it, the front is Mach 1 made in France with a Sachs hub and the rim is of adifferent design. So a wheel has been replaced I guessing it's the front because the bike was made in Taiwan and can't imagine them importing wheels from France.

The front wheel feels like much better quality and runs freely so I'm leaving it alone. There's a metal cover with the Sachs Logo, I wonder if it's a sealed unit?

Once the wheels were polished I could't resist putting them on the bike :D

Next job is to get the rest of the bike out of the loft.


Attachments:
Mach 1 rim A.jpg
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Mach 1 B.jpg
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Rear rim.jpg
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Bike.jpg
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 Post subject: Re:
PostPosted: Sun Jun 09, 2019 6:59 pm 
Devout Dirtbag
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Joined: Sun Jul 22, 2018 5:18 pm
Posts: 138
Location: Faffing by the Sea
A bit more work on the Falcon today. It's been mostly clean and polish and bolting bits back on. New sealed BB and tyres fitted, a new saddle might be in order too.

Not sure whether to find a close paint match and touch up the frame or just wax it.

Next bit is the scary one, brake and gear cables!


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PostPosted: Sun Jun 09, 2019 7:34 pm 
Retro Guru

Joined: Tue May 11, 2010 6:39 pm
Posts: 1217
Location: South Devon
Looking good. I like these. Nail varnish is often an easy way to find a good match for small touch ups, although personally I like a bit of patina...


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 Post subject: Re:
PostPosted: Mon Jun 10, 2019 10:10 am 
Old School Grand Master
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Joined: Sun Mar 14, 2010 2:33 am
Posts: 3744
Location: Kentcestershire
Regarding brake and gear cables, I used to dread cabling, but having the right tools makes the job much less effort.

Get a decent set of cable cutters, it makes the job so much easier than faffing around with the cutters on pliers or standard side cutters. You can find good ones that look suspiciously similar to those sold by bike brands for around a tenner: https://www.ebay.co.uk/itm/UK-Bicycle-C ... SwLiVcwUy5. I've had a pair that look identical to this for quite some time and they work really well.

An engineers scribe, or something pointy that's similar, is useful for re-opening the cut ends of the outer cables: https://www.ebay.co.uk/itm/Engineers-Do ... Swal5YCNu2, I leave one in my bike tool box just for this purpose.

https://www.youtube.com/watch?v=66IYOM9ITWk


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 Post subject: Re:
PostPosted: Mon Jul 15, 2019 9:10 pm 
Devout Dirtbag
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Joined: Sun Jul 22, 2018 5:18 pm
Posts: 138
Location: Faffing by the Sea
Finished. Goes, shifts, stops. :shock:

Might put up some better pics when I go for a proper ride.


Attachments:
Falcon 2.JPG
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Falcon.JPG
Falcon.JPG [ 313.73 KiB | Viewed 1150 times ]
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 Post subject: Re:
PostPosted: Mon Jul 15, 2019 9:26 pm 
Retro Guru

Joined: Tue May 11, 2010 6:39 pm
Posts: 1217
Location: South Devon
Well done! A functioning bicycle! :)


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