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A Journal Of My Restoration Adventures, So Novices Can Learn From My Success and Failure.
The is my latest and most challenging restoration.
I tentatively purchased this 1972 PR10 on EBay in August 2008 for $100 from a seller in Los Angleles.
According to the advertisement, the bike was ridden by the original owner for one year, was heat damaged, but the paint was
in remarkedly good condition. The seller added upon inquiry that he had ridden the bike for a few years before storing
under cover, and that it had original components. However, from the photos and upon inspection it was evident
that the bike had been exposed to the elements and the wheels, handlebar and stem replaced in the late 1970s. Unfortunately,
the backside of seat tube received a large dink (small dent) and some scapes from the blunt end of a quick
release skewer during shipment. Nonetheless, I believe the bike has significant potential, and will offer many
challenges.




The paint and decals are actually in good condition, except for the damaged seat tube. On the other
hand, the steel components show a lot of rust, and the aluminum a lot of corrosion. Luckily, Ted Carl wrote excellent
threads on VintageBMX.com describing rust removal using oxalic acid and aluminum polishing.
I purchased oxalic acid from Hy-Tech Thermal Solutions, and soaked the steel parts in an acid solution (2
oz. per gallon of water) for 24 hours. Before and after photos are shown below.
| Seat Tube Before |

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| Seat Tube After |

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My dad's 1972 AO8 was my first restoration and the adventure is archived below.

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| Dismantled 1972 AO8 |
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Tuesday, March 6, 2007
Cable Reassembly
Luckily, my local bike shop had old new old stock white Schwinn rear brake cables and housing available.
I used the housing for routing both the brake and shift cables. Adjusting the brakes and derailleurs was straighforward
following Zinn's text.
8:12 am est
Freewheel Removal and Axles
The Cyclo freewheel was easily removed using an original Cyclo freewheel tool purchased from Bikeville.com. Apparently,
the Park freewheel tools do not fit. As a precaution, I used a nut and washer on the axle to hold the tool against the
freewheel to avoid stripping the notches in the freewheel core, as recommended by both Sheldon Brown http://sheldonbrown.com/freewheels.html and by Zinn's text. I chose not to attempt a freewheel disassembly which is discouraged by Sheldon Brown.
Axles were thoroughly cleaned, repacked using Phil Wood's Waterproof Grease, and tightened following Zinn's text.
8:10 am est
Wednesday, February 14, 2007
Cleaning the Derailleurs and Brakes
Simple Green and a toothbrush works well, although a fair amount of elbow grease is needed. I also used Old Roads
bike cleaning kit http://oldroads.com/clean_kit.html (bronze wool and 'Menotomy Mixture') to 'smooth' the metal parts.
9:48 pm est
Rebuilding the Headset
Rebuilding the headset following Zinn & The Art of Road Bike Maintenance was a breeze compared to rebuilding the
bottom bracket. The top set of ball bearings were fixed in a race, while the bottom set were loose. As with
the bottom bracket, I re-used the ball bearings and used Phil Wood's Waterproof Grease. Not too difficult to get
the right tightness.
9:47 pm est
Stubborn Cotters Re-visited
Be sure to purchase the Peugeot-cut cotters sold by Harris Cyclery. Even with these, I had to file the cotters
to get the right fit using a flat file and vice as described by Sheldon Brown in his 'newer' Tool Tips Cottered Cranks article
http://www.sheldonbrown.com/cotters.html. I am glad I purchased the cotter press, because I had the cotters in and out at least a dozen times. Even now,
the cranks are about 5 degrees off of 180 degrees. I will take it!
9:43 pm est
Bottom Bracket Rebuild
No problem re-building bottom bracket. I squirted LPS-3 Heavy Duty Rust Inhibitor into the tubes. I then
inserted an accordian-like bottom bracket sleeve, purchased from Harris Cyclery, to prevent crud from the tubes getting to
the bearings. I used Phil Wood's Waterproof Grease and re-used the loose ball bearings to re-pack the bracket.
I also purchased a modified Horzan Hook Spanner from Harris Cyclery to tighten the lock ring. Sheldon Brown's 'safe
cracker' technique http://www.sheldonbrown.com/tooltips/bbadj.html worked well for getting the lock ring and adjustable cup just right.
9:29 pm est
Saturday, January 20, 2007
Even More Stubborn Fixed Cup
The headset and bottom bracket, except for the fixed cup were easily removed from the bicycle. I tried a variety
of techniques to remove the fixed cup including heating with a blow torch, and using a large crescent wrench and hammer combination
to no avail. I then read Sheldon Brown's 'Tool Tips' article on 'Bottom Bracket Cups' http://www.sheldonbrown.com/tooltips/bbcups.html and learned that for my reburbishment project I shouldn't be removing the fixed cup, and furthermore I was using the wrong
methods. Consequently, I have decided to read all of Sheldon Brown's "Tools Tips' articles http://www.sheldonbrown.com/tooltips/index.html before continuing with this project.
6:22 pm est
Friday, January 5, 2007
Stubborn Cotter Pins
Sheldon Brown indicates that cotter pin removal can be one of the most challenging hurdles to overcome when disassembling
a bicycle, and I can now attest to that. I purchased a cotter pin press from Bike Smith Design & Fabrication http://bikesmithdesign.com/CotterPress/index.html. It worked well on the non-drive side crank arm, but the drive-side cotter pin was too stubborn and the threaded-end
of the pin snapped off. I then used Sheldon's hammer and pipe technique, substituting for the pipe a 2"x4"
wooden stud with a hole drilled in the end to receive the pin head. This approach also did not work. Lastly, I
purchased 1/8" and 1/4" DeWalt cobalt split and pilot point drill bits and drilled the cotter pin out. This was not
too difficult once I had the right bits in hand.
9:12 am est
Tools
I decided to purchase some bike-specific tools for the project and to maintain my other bicycles. I went with Park's
Advanced Mechanic's Tool Kit. Nice set of tools, but does not come with a torque wrench, toothed lockring spanner, or
pin spanner, all of which I would like to have.
8:52 am est
Monday, January 1, 2007
Reference Documents
Since I am a bicycle mechanic novice, I needed reference texts and manuals before embarking on my restoration
project. I recommend Lennard Zinn's "Zinn and The Art of Road Bike Maintenance," published by Velo Press. It is
excellent with lots of illustrations and easily understood narrative. Also, Sheldon Brown's and Tom Kunich's articles
on maintaining, upgrading and modernizing French bicycles are invaluable and available on the Harris Cyclery website.
1:20 pm est
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2007.03.01 |
2007.02.01 |
2007.01.01

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This website was last updated 15 October 2009
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