Another 90’s Peugeot rebuild

[Tzantushka]

Fellow Peugeot lovers…

Finding inspiration from Macca's thread – I have decided to undertake a project…

Since upgrading to a ’14 LaPierre Sensium the Peugeot is in the workshop for a heavy maintenance visit ( kinda like an aircraft 'D check' for bikes).
I’ve had this bike since brand new (about 1990) and since then it’s been reliable, comfortable albeit a bit weighty!

Virtually all of the grouppo is original except for:
- Brake levers due to wear & tear (replaced with Exage motion instead of the original Exage action)
- Rims for durability (changed to Campy Atlanta’s back in '96)

Before overhaul...



Action brake callipers getting some love





Biopace chainwheel having a birthday



New cables, tyres, bar tape and chain are on their way...

More to come.

[macca33]

Great work mate! I miss my Aubisque, but sold as it was just too small - luckily it was to a mate who gets it out for a run every so often. Looking forward to your updated progress.

cheers

[GaryF]

It's very nice to read that you are the original owner and have committed to this bike as you are doing what is necessary to keep in in great condition.

[Tzantushka]

Reconditioned stem & handlebars
- new bar tape (essentials cork white)
- new shimano SLR cables (man, what a difference!!)
- cleaned & polished stem
- one of the brake levers needed a new spring (hoods were OK)



Impressed with the Shimano brake kit.
Stainless inner with teflon and outers have a polymer coating on the inside.
Even comes with ferrules and cable ends.

[Tzantushka]

Productive day today, addressed the rear wheel & cluster.
This was the major issue as the freewheel was doing just that - freewheeling even under pedal load.

It has a Suntour Alpha 13-22 cluster requiring a 4 prong free wheel tool.
The good news is the hub and rim survived.




But the freewheel body didn't.



I see why Suntour flamed out... What a POS design that is.

Well now, I'm on the hunt for a replacement 6spd freewheel cluster to suit a hub with a thread diameter of 34.72mm (35mm?)

[Tzantushka]

Front wheel also received a makeover.
- clean
- check for trueness
- re-grease
- new tube & hand-me-down tyre

French Maillard hubs were in great condition given their age:



I've found the following tools make life much easier:
- syringe with bearing grease
- old surgical tweezers help with rectreiving & placing bearings
(picked up a pair for $1 at the Camberwell Sunday market)



All done awaiting fitment:



Also another tip for cleaning the brake tracks.
Superfine steel wool (#0000) and a 30% phosphoric acid + water solution (e.g. Bondall Ranex Rustbuster)
Quick scrub and rise cleaned off all the old contaminated brake pad

[baabaa]

I see why Suntour flamed out... What a POS design that is.
You really need to fit your freewheel remover and then snug it down a bit with your axle bolt or QR before you try and get it off.
The four prongs are much better than the two, good single speed freewheels ( like white industries) still use a four prong removers so it is not the design.
Maybe try for a Suntour Winner Pro or Winner Ultra freewheel which are good units and have a very long life.

[Tzantushka]

This cluster was a Suntour alpha -so you are right. Not as good as the Winner freewheels.
Even with the removal tool snug down on the axle and a skewer for lateral support - it camed-out.
At least with the Shimano splined design, there's no risk for the tool to cam-out once you apply significant force.

After 15+ years it was fused on.
Appears the previous LBS didn't apply anti seize to the hub thread.
This time I'm going with a leg friendly Shimano 14-28 freewheel

[Tzantushka]

The saddle was looking pretty tired.
The original vinyl after 20+ years had a few cracks.

For practical and fiscal reasons, ended up going for some white marine vinyl.
Easy clean and can stand up to the weather.

Out with the old...



Covering with the new...


The underside is a bit rough, and there's a few areas where I need to re-stretch the vinyl.



But it works for a first effort.

[QuangVuong]

Good first effort in recovering. The material looks a little bit thick, and is why you've got a bit of wrinkling going on. With the thinner materials, you can stretch out the wrinkles and hide them the under side of the saddle. And you seat clamp is on the wrong side. Unless you want a forward set seatpost.

Anyway, it's cleaning up well so far.

[utedeej]

This cluster was a Suntour alpha -so you are right. Not as good as the Winner freewheels.
Even with the removal tool snug down on the axle and a skewer for lateral support - it camed-out.
At least with the Shimano splined design, there's no risk for the tool to cam-out once you apply significant force.

After 15+ years it was fused on.
Appears the previous LBS didn't apply anti seize to the hub thread.
This time I'm going with a leg friendly Shimano 14-28 freewheel

Even with a Shimano remover, I once busted it apart trying to remove a cluster.

Nice work on the cleaning and build.

[Tzantushka]

Good first effort in recovering. The material looks a little bit thick, and is why you've got a bit of wrinkling going on. ... And you seat clamp is on the wrong side. Unless you want a forward set seatpost.

Thanks QV - you're right the material is a bit heavy and I don't think I stretched it enough before applying the glue.
Oh and the seatpost clamp - you have an eye for detail!

Even with a Shimano remover, I once busted it apart trying to remove a cluster.
Nice work on the cleaning and build.

Thx.
Good to know clusters can be troublesome for anyone!

[Tzantushka]

Good first effort in recovering. The material looks a little bit thick, and is why you've got a bit of wrinkling going on. ... And you seat clamp is on the wrong side. Unless you want a forward set seatpost.

Thanks QV - you're right the material is a bit heavy and I don't think I stretched it enough before applying the glue.
Oh and the seatpost clamp - you have an eye for detail!

Even with a Shimano remover, I once busted it apart trying to remove a cluster.
Nice work on the cleaning and build.

Thx.
Good to know clusters can be troublesome for anyone!

[baabaa]

Good to know clusters can be troublesome for anyone!
They really have been designed to work with a bench vice holding the remover very tight. Oh, and keep the tube and tyre on. And, even better pumped up higher than you would ride to help you get a real good hand grip on the tyre before you twist your wheel. But yeah, they can be stubborn.

[Tzantushka]

Started on the frame on the weekend.
Usual chips and scuffs resulting in minor rust spots.

I'll try and keep the decals for originality.
But this means more work masking, spraying, sanding, feathering and spraying to blend the edges.

Forks had the most rust.
Rust converted, primed & filled - note the hard masking edges...



Feather back the primer around the decal & spot fill any dodgy areas...



Now the frame...



Bit of a bugger as there was rust under the chainstay decal...



I must say, repainting bikes is much harder than cars, as there are sooo many rounded edges .

[QuangVuong]

New decals are available on eBay if you need them. Good to see someone go to great efforts in paint touch up

Also, this would be a pre 91 Peugeot going off the DT font.

[macca33]

Yep it is 88 - 89 this one. Great work Tzantushka!

[ldrcycles]

They really have been designed to work with a bench vice holding the remover very tight.

This is what i was going to suggest, it wasn't long ago that i discovered that trick from one of the local shops and it makes things SO much easier and safer.


Great work on the restoration, impressive attention to detail.

[Tzantushka]

Thanks guys.

You don't do this to make money...
Seeing as It's my first roadie as a a teenager I'm doing it for emotional attachment!
(and a retro ride with the group now and again).

I had a squiz on ebay for the decal set, but couldn't find the Abisque ones.

Did manage to find the chainstay one though...

[QuangVuong]

http://www.ebay.com.au/itm/140975258217" onclick="window.open(this.href);return false;

[Tzantushka]

http://www.ebay.com.au/itm/140975258217

That's awesome QV...
I searched for Peugeot decal on ebay, came up with everything BUT these ones...

In the meantime, the cranks & chainring came-up a treat.

Before




After





120 grit flapwheel to take out the deep scratches & gouges.
240 wet & dry rub-down
800 & 1200 final sand
Autosol on a calico mop wheel for a re-polish
Autosol shine for final polish on a soft cotton mop wheel

[Tzantushka]

Frame is well underway...

- 240 grit sand
- spot primed & filled
- 600 grit wet sand
- ready for masking + colour coat



Will probably run with 4 coats of acrylic, colour sand, compound & polish.

[ldrcycles]

Cracking job on the cranks, they look fantastic.

[Tzantushka]

Cracking job on the cranks, they look fantastic.

Thanks. Shiny alloy is nice!

Frame is done.
As usual, most of the time is spent in the preparation, rather than the painting!

The spray booth… Complete with spray paint jig!
I don’t have an enclosed shed, so I had to pick my day according to the weather.



4 x light coats with 5 mins flash-off between coats
1 x med coat ensuring any wet edges are blended
24 hrs drying time

The dried finish was actually quite good, so finishing & polishing was straightforward.
Wet colour sand with 1200 grit
First polish with Menzerna intensive polish
Final polish with Menzerna Super Polish & buff with microfiber cloth.

Test fit of a few components..





The only downside, was some of the clear sections of the decals were yellowed with age.
I’m cool with that, as the edges are blended nicely.
Plus original decals make the bike look – er… original!



Will give the paint a few more days curing time before assembly.

[macca33]

Again....very nice mate!