Ruf'nRusty - Finished! - 28 Jul 11

[jerrykr]

Spent a good part of Memorial Day taking this rusty thing apart.
The seat post is totally stuck. Got to find a way to deal with it next.

Here's the pile'o'parts so far.



You guys are building some great looking bikes!

[jerrykr]

OK, got the wheel set cleaned and repacked. Getting the Shimano coaster back together was interesting to say the least. I *think* I could do it again!

The rims in paint - etching primer.



I decided to try a suggestion I saw somewhere here, don't remember who posted it, but I used a rattle can of spray on bed liner to get a pretty nice textured paint on the rims. Thanks for the idea - whoever posted it!



These 2 rims represent a whole rattle can. I can't imagine how many cans it would take to paint a whole pickup bed.

Next they go into my paint dry oven -- my attic. It's upwards of 110F up there every afternoon. That should dry the paint!

[jerrykr]

This is the day I've been dreading and putting off until I had a full day to attack it.

Father's Day worked out good for me, as my sons are grown and away, and Sheryl had to work, so I had the day to myself. Only drawback is that it must have been 104F and high winds all day. Crazy weather here! And crazy builder, to choose a day like today to do gas welding! But, Aug. is creeping up, and this bike won't build itself.

As I've said before the seat post in this frame was Major Stuck. I've been soaking it in PB Blaster for a month, and tried every trick, and it just wouldn't budge. So, I decided to cut it off flush with the seat tube and drill it out with a long 13/16" drill bit I have.



Sounds simple, but believe me this is not easy. I charged my drill motor batteries 4 times in the process, and it took hours, but I finally got it drilled out of the way. My right wrist is going to be hurting tonight. That drill motor has some impressive torque, and a few times the bit grabbed and wrenched my wrist around. Funny thing was, it made me pull the trigger all the harder, I could not get off the "gas".



Losing the original seat post was pretty much in the "plan". I wanted to try to build my own laid back seat post anyway. I had previously purchased a couple of lengths of 13/16" round steel bar stock for this very purpose. I also have a new unused 7/8" laid back seat post to use as a pattern.



I wish I had a MIG or TIG electric welder, but I don't, so I stuck this together with my Oxy-Acetylene gas rig. I don't weld often, so I was kind of out of practice, and the results show, but I don't think anything will fall apart. I got it primed and painted, but need to do a little bit of "Bondo Welding" to make it look better. Ran out of time and energy today, Dang it was HOT!



Sorry there were very few pictures, but my hands were dirty and I think you can fill in the blanks!

Should start going together now that I'm past this hurtle, and a lot of the parts are prepped and cleaned.

I still need to create a couple of brackets for the lights. I think you will like the lights I'm going to use.

Stay Tuned!
.

[yoothgeye]

Just an idea for "next time"... they used to make drills that plugged in.

[jerrykr]

yeah, but the one I have doesn't have a big enough chuck for that drill bit!

[yoothgeye]

yeah, but the one I have doesn't have a big enough chuck for that drill bit!

Understandable. How much reeming out of the tube happened? Does it still clamp a post alright?

[jerrykr]

It did enlarge the inside of the tube some, but I don't think it will be a problem clamping the seat post.

I'd put this job in the "last resort" category.
I tried everything I could think of, but that post was stuck in there really well.
It did save the frame however, and did not mess up my rust finish.

[yoothgeye]

I'd put this job in the "last chance" category.
I tried everything I could think of, but that post was stuck in there really well.
It did save the frame however, and did not mess up my rust finish.

With my aim the big bit would've come right out of the side.

We did a little painting last night, but it was outside, just wanted to share. That wasn't on my RRBBO bike, but I did get some done on it last night, and today I'm headache free!

[jerrykr]

Good on ya! We have had some crazy hot winds here, so my painting of the seat post was a challenge, but also blew any 'fumes" away very quickly.

Honestly, I was watching my progress, to make sure I didn't drill out the side of the seat tube. My 'drill" was not exactly straight, but it never went near the outside of the seat tube.

[jerrykr]

Been awhile since I found some time to work on this beast.
I've been sweating my bottom off doing some outside home repairs.

Anyway decided to get some progress made on the bike today.


Tires mounted.
Hub and brake re-packed.
Spokes tightened.



Checking the fit for my valve stem caps (literally).



I know it's been done before, but here's basically what it takes to make 'um.
Just select some brass that the plastic valve cap will fit into. These were 7.62 rifle rounds.
Cut to length,
Mix up some glue and put it down inside the brass.
Push the plastic cap in all the way and let the glue set up.



Some detail parts out of paint.



Got the greasy parts assembled.



Some front end assembly.



Time to post pictures inside in the A/C. It's well over 100F out there right now.

.

[ChrisMac]

Lookin' good. the rust is working for ya.

[scott brownsey]

very cool cant wait to c it done

[jerrykr]

I got a lot of it put together this week-end dodging the afternoon heat. Over 100F here every day by about 2 PM.

Still quite a bit to do, but here's what it looks like now. It rides pretty good with the laid back seat.







.

[MplsCoaster]

Hey Jerrykr,

Congrats on your ride!
Glad to here it rides good.

The seat and seat post combo gives it an unique look.
I like the way the seat, tires frame are matching and
then the bars, seatpost, and wheels match.

Stay Cool

[jerrykr]

Thank you mplscoaster, glad you like how I'm trying to make things match.
The look will follow that direction even further next week-end.
It's just too hot to do anything after work during the week.
I just wanted to make sure everything functions today.
I'm pretty much pleased with my efforts to take a completely locked up rust bucket to rideable,
but I'm not the only one to ever do that!