Re:
So fast forward a few months since my last post, and the Courier rebuild is complete. Having two young kids I've focussed on getting it finished for the summer instead of documenting every single step. I'm pleasantly surprised with how it turned out, it actually works really well. The BB came up like new and spins forever. The front hub just got stripped down and rebuilt with new bearings. The rear hub was much more challenging. I wanted to use a Followme tandem with it, but the adapters only come in M10 and M12 axle diameters. The Sansin hub had an 9.5mm X 26tpi axle so necessitated change. I rebuilt it with an M10 wheels axle, cones, G10 bearings, and an amalgamation of spacers and seals to get it centred and working ok. Both wheels got rebuilt with DT stainless spokes.
Most of the time was spent polishing all the alloy components and cleaning up the frame. I used a lot of T-cut on the frame to get the rust stains out. All open rust spots were treated with a rust convertor. The whole thing was the heavily waxed to preserve it. As I think I originally said it was never supposed to be a full restoration as I wanted to preserve the patina and character.
The build has come together quite nicely. I still have a few things to do, get some fenders for it, a front rack bag etc. It has been great so far what what I originally wanted it for, that is pulling the 3yr old around.