Boscarn
rBotM Winner
I have previously posted finding this 1937 Sun Wasp, viewtopic.php?f=23&t=319153.
A lot of progress has been made since then, soaking in WD40 etc and a full dismantle revealed that the bike was in a very poor state. I bit the bullet and started a full rebuild.
The frame was totally stripped, except for the head badge. I found a local chrome works that would re-plate the fork ends (they also re-plated the stem and seat post at the same time) the old paint removed, de-rusted, primed and painted black. Some decals were obtained from H Lloyd applied and coat of lacquer applied to protect them.
The wheels came next, the Sturmey Archer, three speed drum hub had seen better days, basically no gears could be used, after stripping and inspecting, it was buggered. The front hub was not much better. Luckily, I managed to find a refurbished replacement that had been re plated (nickel) and a suitable front hub. The rims, Dunlop 26” stainless, have been re used and laced up using stainless spokes. The front hub needed some new cones, unfortunately, the ones I had are a fraction smaller than original, but they work well.
Next, the Resillion front brake, I did modify some 72mm MTB brake pads, but luckily I found originals on EBay. However, they were for same side! To make a pair, one was modified by removing the brake block stop and soldering one on the other end. A good clean and a little paint to restore the calliper, the front brake cable had been made from a BMX giro cable and some grub screw clamps that did not work. A new giro cable, complete with adjusted was purchased, (I looked for an age to find a good used Resillion one without any luck), I found that spoke nipples would make great ends as they fitted the brakes and lever perfectly. After cutting the cables to length, tinning all parts, the nipples soldered on very easily using a 50W soldering iron.
The bars had some form of wrapping that the rain had got under and was peeling off; all removed a coat of satin black applied and some new grips fitted. The saddle was shot and replaced with an old brooks B17.
The mudguard came up well after cleaning, the stays painted with some silver paint, they were designed to be quick to remove, so a modified support employing a Terry clip fitted. One pair of the wing nuts have been replaced with some modern ones. Again, the saddle bag support re-painted and fitted.
The chain set was a problem, the bottom bracket, NBG and crank arms so badly worn the axle rattled around in the hole! I had a new TDC axle and found a pair of Williams Cranks from the 60’s that looked identical, but will little wear. The original chain ring was in good order and refitted. The bottom bracket shell is 66mm, but fiddling with various cups from many manufactures, a pair was found fitted and works well. The Phillips rubber pedals replaced with some Phillips Apollo.
The only item left is the head clip, the one fitted is worn, badly worn, but it does work with new bearings. The steering is a little heavy and it needs to be replaced, any help gratefully received.
Finally, the Miller dynamo light removed cleaned and sprayed, the internal contacts cleaned and tested. All working, accept for the internal battery. I have not fitted the refurbished lights, they will only add to the weight of this beast
A lot of progress has been made since then, soaking in WD40 etc and a full dismantle revealed that the bike was in a very poor state. I bit the bullet and started a full rebuild.
The frame was totally stripped, except for the head badge. I found a local chrome works that would re-plate the fork ends (they also re-plated the stem and seat post at the same time) the old paint removed, de-rusted, primed and painted black. Some decals were obtained from H Lloyd applied and coat of lacquer applied to protect them.
The wheels came next, the Sturmey Archer, three speed drum hub had seen better days, basically no gears could be used, after stripping and inspecting, it was buggered. The front hub was not much better. Luckily, I managed to find a refurbished replacement that had been re plated (nickel) and a suitable front hub. The rims, Dunlop 26” stainless, have been re used and laced up using stainless spokes. The front hub needed some new cones, unfortunately, the ones I had are a fraction smaller than original, but they work well.
Next, the Resillion front brake, I did modify some 72mm MTB brake pads, but luckily I found originals on EBay. However, they were for same side! To make a pair, one was modified by removing the brake block stop and soldering one on the other end. A good clean and a little paint to restore the calliper, the front brake cable had been made from a BMX giro cable and some grub screw clamps that did not work. A new giro cable, complete with adjusted was purchased, (I looked for an age to find a good used Resillion one without any luck), I found that spoke nipples would make great ends as they fitted the brakes and lever perfectly. After cutting the cables to length, tinning all parts, the nipples soldered on very easily using a 50W soldering iron.
The bars had some form of wrapping that the rain had got under and was peeling off; all removed a coat of satin black applied and some new grips fitted. The saddle was shot and replaced with an old brooks B17.
The mudguard came up well after cleaning, the stays painted with some silver paint, they were designed to be quick to remove, so a modified support employing a Terry clip fitted. One pair of the wing nuts have been replaced with some modern ones. Again, the saddle bag support re-painted and fitted.
The chain set was a problem, the bottom bracket, NBG and crank arms so badly worn the axle rattled around in the hole! I had a new TDC axle and found a pair of Williams Cranks from the 60’s that looked identical, but will little wear. The original chain ring was in good order and refitted. The bottom bracket shell is 66mm, but fiddling with various cups from many manufactures, a pair was found fitted and works well. The Phillips rubber pedals replaced with some Phillips Apollo.
The only item left is the head clip, the one fitted is worn, badly worn, but it does work with new bearings. The steering is a little heavy and it needs to be replaced, any help gratefully received.
Finally, the Miller dynamo light removed cleaned and sprayed, the internal contacts cleaned and tested. All working, accept for the internal battery. I have not fitted the refurbished lights, they will only add to the weight of this beast
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