1992 Explosif Pro project.

Teggers

Old School Hero
As I threatened when I first joined at the start of lockdown, I have finally started putting together my Explosif.

Warning: I am NOT taking it back to original factory spec so if this irritates you, I don't care as it's my bike not yours :p

A brief history of the bike: I bought it new in 1992 as old stock in a sale having worked in a plastic injection moulding factory for £2.50 an hour for my entire school summer holidays to afford my first decent bike. I managed to get a good deal and have a set of Rock Shox Mag 21's included. Can't remember how much it was all in but I think it all ended up being about £1000 give or take a bit. Not being one to leave things alone, I extensively changed parts over the subsequent few years to the extent that when I came to look at it as a project this year, not a lot of the original was left.

It was used as variously as a commuter, race bike (early to mid 90's during which I managed to break the Mag 21's), university transport, method of seeing the girlfriend of the time and, of course, its proper use as a trail bike. Then in 2009 it was relegated to the back of my garage as I bought a Felt Q520 (again, end of year clearance sale!)

I have spent a lot of time online during lockdown browsing for parts and deciding how I wanted to go with my build. In car circles, it's called a restomod. Examples to put it into perspective for anyone who doesn't know what this is, think a '60's musclecar (Mustang/Camaro etc) with a new crate V8 with a blower or a nice old barn conversion house with new electrics and plumbing. So there are carbon bits, new model parts, older parts and, yes, even a few period correct parts!

Decided on a black and silver theme with red highlights/trim to match the red highlights of the lettering.

I'm still waiting for a couple of parts to arrive and the build will now be done as and when I have time as I'm back at work on Monday.

Pics go from the bottom up in terms of progress...
 

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No welding. Can't to the carbon forks! Sticking with a set of NOS v brakes and my concession is a clamp on cable stop at the rear of the top tube* Had to be a double as the singles all would have had the bolt in the wrong place and I couldnt find one to go round the seat tube to replace the plastic guide for the old canti brakes :( it's not an elegant solution but it is a solution for now.

If anyone has a black, red or silver suitable clamp I'd be interested.

* this one: https://www.sjscycles.co.uk/gear-spares ... top-black/
 
I finally have all the bits needed (bar rear brake cable routing. More on that in a sec) as I just won some carbon handlebars on the dreaded bay of e. A set were ordered when I first started but they have still not arrived from the "UK seller" who, it seems may well be based in the UK but his parts seem to come from China according to the tracking info. 2 months later they still haven't arrived so I started looking on eBay and the 6th or 7th auction I was involved with is the one I actually won. Being a bit daft I also put a bid on another set of handlebars before I won these and currently winning those as well so I may end up with 2 sets.

Started looking at fitting the headset and the cost of headset presses or getting a bike shop to do it for me (the ones here don't seem to be interested. Or open). They don't seem to be very complicated tools that people seem to want £50 to £60 for them and I believe I can make one myself with some threaded bar, large bolts and a couple of plywood drifts. I have the bits and facilities to make them so let's see how that goes!

There's a little bit of of grinding/sanding to do on the frame around the mounts for the v brakes and and the lugs to attach the wheels as there's a lot of powdercoat there that's stopping them from being slotting in/on properly. I had the same issue with a car when I had suspension arms powder coated and then had to grind them down to be able to fit the bushes. A Dremel is your friend here!

I've been puzzling over ways to route my rear brake cable on a v-brake conversion in a sensible, logical and aesthetically pleasing way. Tried a problem solver but they only have a 2 cable stopper that fits and I don't really want it on the top tube. Thought about just running full cable with outers with 3M cable clips. If I'd planned this far ahead I could have had a stopper brazed on in the right place prior to powdercoating but too late for that now...

Either of these will do the job and work but neither are particularly pretty. Ideally for my previously canti'd Explosif that now has V-brakes the dog collar looks like the best option. But I'm struggling to find one or when I do the seller (ebay) wants the earth for it. To this end I've message to seller on here that may have what I'm looking for and I'm currently waiting for a reply.

No more pictures at the moment as I haven't actually assembled anything I just have a big box of parts.

Now I'm back at work (8-10 hour days) I won't have all the free time in the world but theres no hurry and I'll update with details and pics when more is done.
 
Ok. I did actually finish this a few weeks ago but haven't had time to sit and post everything.

Apologies but due to my ridunkulously slow internet (circa 1mpbs, yes, that's 1meg when most are probably on 20+ by now) I'll put 1 pic per post or it will take hours to upload them even with reducing the size.

First is all the collected parts and some shiny new tools. A handful of parts are re-used like the cranks I posted above (original Shimano ones polished up lots!) But most are new.
 

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Firstly was the installation of the new Shimano BB. Note the makeshift workbench and using an old workbench with a towel to protect the paintwork.

Prior to anything being fitted, the frame was filled with lots of ACF-50 anti corrosion spray. I did a lot of research as to the best product to use and this came up time and again. Not the nicest and I made a bloody mess of the patio, much to the missus' annoyance, but it should do the job nicely. There was much spraying into small holes, dripping out of drain holes, turning and making sure every nook and cranny was protected. I probably used a lot more than I needed but I dont want the frame to corrode inside out!

Lots of grease was used as well in the installation process. The black tub is Silkolene lithium grease. All black as I dropped it once and cracked the tub... so fixed it with black tape!
 

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Next, on went the FSA MX headset. Home made press worked perfectly!
 

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