A colleague asked me to find her a road bicycle for up to around 200 euros. Since small sized frame 2nd hand bikes offer was very poor, it was decided to find a frame and components and assemble a nice fast bike. 🙂
1. Sourcing parts and preparations
Suitable frame was found. Old Peugeot road frame with chromium-molybdenum Columbus tubing.
![Frame for the project](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0058_ram_pre_peskarenja-1024x768.jpg)
Next came the groupset. Shimano 600 brakes and brake levers, with SunTour derailleurs and shifters. Crankset was Shimano BioPace 53-42. It all needed some cleaning and lubing.
![SunTour front derailleur](https://bike.bikegremlin.com/wp-content/uploads/2017/05/fd-1.jpg)
![Shimano BioPace chainrings](https://bike.bikegremlin.com/wp-content/uploads/2017/05/lancanici-1.jpg)
![SunTour rear derailleur](https://bike.bikegremlin.com/wp-content/uploads/2017/05/rd-1.jpg)
![SunTour rear derailleur](https://bike.bikegremlin.com/wp-content/uploads/2017/05/rd-2.jpg)
After some cleaning, this is what it looks like:
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0001_delovi_oprani-1.jpg)
![Clean parts - like new :)](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0002_delovi_oprani-2.jpg)
![Steel wool and spunge - main tools for returning the shine](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0049_metalna_vuna_i_sundjer-1024x768.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/kraj-restauracije-1024x768.jpg)
2. Restoring hubs and wheels
![Rear hub before the overhaul](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0004_zadnja_nabla-pre-768x1024.jpg)
![Inside of the rim before cleaning](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0007_unutrasnjost-felne-pre-768x1024.jpg)
![Rim mark](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0008_oznaka_felne.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0010_zupcanici_pre-768x1024.jpg)
![Rim braking surface damage](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0012_ostecenje_felne.jpg)
![Coarse sand paper 220 grade, for repairing rim brake surface damage. Later, finer sand paper of grade 600 was used](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0014_smirgla-220.jpg)
![Sanding the rim](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0017_smirglanje-felne.jpg)
![Repaired rim brake surface. No more big grooves](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0018_sanirana_felna.jpg)
Rim and spokes were cleaned and nipples lubed with “light” oil to help truing the wheel.
![Cleaned rims and spokes and lubed spoke nipples](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0045_oprani_tockovi-768x1024.jpg)
Next came hub overhaul. Instructions how to do it are given in this post: Bicycle hub overhaul.
![Removing cassette lockring](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0021_uniglide-lockring-1024x768.jpg)
![Shimano tidiness: each spacer and sprocket order is marked](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0022_shimano-pedandnost-1024x768.jpg)
![Cleaning and removing old grease](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0024_skidanje-stare-masti-1024x768.jpg)
![Clean, spotless cone](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0025_srednjen-konus-1024x768.jpg)
![Clean, spotless cup - old Shimano quality :)](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0027_cista-leva-solja-1024x768.jpg)
![Freehub body removed](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0029_rastavljen-nosac_freehuba-1024x768.jpg)
![Freehub seat coated with copper grease to prevent seizing](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0030_bakarna-mast-na-leziste-freehuba-1024x768.jpg)
![Freehub holding bolt coated with copper grease](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0031_bakarna-mast-na-nosac-freehuba-1024x768.jpg)
![Screwing freehub back on](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0033_vracanje-freehuba-1024x768.jpg)
![Placing new bearing balls](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0034_vracanje-kuglica-768x1024.jpg)
![Copper grease coated axle lockring - to prevent it from siezing](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0036_bakarna-mast-na-lockringe-768x1024.jpg)
![Cassette lockring coated with some copper grease](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0037_bakarna-mast-na-zupcaniku-uniglide-768x1024.jpg)
![Dirt inside the hollow axle](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0046_suplja_osovina-pre_brisanja-768x1024.jpg)
![Cleaning the hollow axle](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0047_brisanje_suplje_osovine.jpg)
![Squeaky clean hollow axle :)](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0048_obrisana_suplja_osovina-768x1024.jpg)
Finally, it was all assembled together and wheels were trued.
3. Crankset assembly
Crankset is Shimano BioPace. It has asymmetric, i.e. not completely round chainrings. The idea is that the diameter is increased near the top and bottom of each stroke (when pedals are at 12 and 6 o’clock). This slightly slows down the transition from upward to downward leg movement (and vice-versa). When cranks are near 3 and 9 o’clock, chainring diameter is effectively smaller, enabling easier and faster movement. This design is easier on the knees when pedalling with more force at a low cadence, and reduces the “bouncing in the saddle” effect when using high cadences.
Most asymmetrical chainrings of other manufacturers use opposite curves – making chainrings with largest diameter at 3 and 9 o’clock pedal position. Like this Rotor’s Q RINGS® chainring design. The idea is to give most resistance in position where a rider can produce most torque, while making it easier in 12 and 6 o’clock position. This design is very bad for the knees, because, when transition from upward to downward movement happens (at top and bottom of each stroke), it lowers resistance, effectively further increasing the turning speed. Effectively – knees and muscles need to transfer from going upwards (and “pulling”) to going downwards (and “pushing”) even faster, than with using round chainrings.
This is why, when mounting BioPace chainrings, proper orientation is very important:
![Shimano BioPace large chainring orientation mark](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0039_orijentacija_biopace-pogona.jpg)
![Shimano BioPace small chainring orientation mark](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0040_orijentacija_biopace-pogona-768x1024.jpg)
![Mounting chainrings with marks aligned with the right crank arm](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0042_orijentacija_biopace-pogona.jpg)
![Key for tightening chainrings onto the crankset spider.](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0043_zatezanje_srafova_sajbni_pogona-768x1024.jpg)
![Key is used to hold the nut in place, while on the other side a 5 mm allen wrench is used for tightening](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0044_zatezanje_srafova_sajbni_pogona-768x1024.jpg)
4. Rear derailleur service
Rear derailleur was completely disassembled, cleaned and re-lubricated:
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0050_rasklopljen_zadnji_menjac-768x1024.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0052_skidanje_tockica_zadnjeg_menjaca-720x1024.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0053_skinut_tockic_RD-a.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0054_rasklopljen_tockic_RD-a.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0055_podmazivanje_rd-a-768x1024.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0056_cist_i_sjajan_RD-768x1024.jpg)
5. Frame restoration
Frame needed sand blasting, then painting, then preparation for all the parts to be mounted onto it.
![Sand blasted frame - bare metal](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0060_peskaren_ram-1.jpg)
![Difference in colour: shows where tubes are welded (practically glued) together with melted brass](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0061_peskaren_ram-2.jpg)
Then the frame was sent to be powder coated.
![Powder coated fork](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0063_ofarbana_viljuska.jpg)
![Check of dropout (and frame) alignment upon the return from powder coating](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0064_provera_poravnanja_dropova.jpg)
Frame measurement and re-alignment should be done before painting, this was just a final check before assembling it. Had there been any damage during transport, it would have shown in this final measurement.
Before mounting parts, all the frame mounting threads needed to be cleaned:
![Mounting threads full of powder coating paint](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0066_neociscena_rupa_na_ramu-768x1024.jpg)
![Cleaning threads](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0067_prociscavanje_navoja_na_ramu-768x1024.jpg)
![Cleaned threads](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0068_prociscen_navoj-768x1024.jpg)
![Cleaning bottom bracket shell threads](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0065_prociscavanje_navoja_pogona.jpg)
6. Mounting headset and fork onto the frame
![Smear of copper grease before mounting headset cups. So they can be easily replaced in the future](https://bike.bikegremlin.com/wp-content/uploads/2017/05/1_priprema_rama_za_montazu_solja-768x1024.jpg)
![Greasing fork bearing cups before placing bearing balls](https://bike.bikegremlin.com/wp-content/uploads/2017/05/2_montiranje_lezajeva_kormana-768x1024.jpg)
![Mounted fork](https://bike.bikegremlin.com/wp-content/uploads/2017/05/3_montirana_viljuska-526x1024.jpg)
7. Mounting all the components onto the frame
![Stem holding bolt and wedge are greased with copper mounting paste to prevent them from siezing](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0005_konus_kormana_bak_mast.jpg)
![Outer part of the steerer wedge (cone) is coated with copper grease to prevent it from getting stuck to the inside of the fork tube](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0006_konus_kormana_spreman.jpg)
![Rear derailleur and rear axle distancers are mounted](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0007_montirani_distanceri_osovine.jpg)
![Copper grease placed on the brake mounting bolts before tightening them](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0008_montiranje_kocnica2.jpg)
![Mounted brakes](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0009_montiranje_kocnica1-768x1024.jpg)
![Frame BB shell coated with some copper grease to enable easier future replacement](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0010_montiranje_patrone_pogona-768x1024.jpg)
![BB cartridge ready to be installed](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0011_patrona-za_ugradnju.jpg)
![Mounting crank arms onto the BB axle](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0012_montiranje_pogona-768x1024.jpg)
![Mounting front derailleur](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0013_kraci_sraf_menjaca-768x1024.jpg)
8. Routing housing and cables
![Routing shifter cables](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0014_sajla_menjaca-768x1024.jpg)
![Rear derailleur cable routed](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0015_zadnji_menjac_rutiran.jpg)
![Routing rear brake housing](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0018_provlacenje_buzira-1024x768.jpg)
9. Final touches
![Seat post and saddle mounted](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0016_stavljeno_sedlo.jpg)
![Bar tape. The best one - Fiz:k :)](https://bike.bikegremlin.com/wp-content/uploads/2017/05/0017_traka_za_korman.jpg)
![Finished! :)](https://bike.bikegremlin.com/wp-content/uploads/2017/05/20170221_072732.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/20170221_072740.jpg)
![](https://bike.bikegremlin.com/wp-content/uploads/2017/05/20170221_072753-768x1024.jpg)
It was a long, but interesting and fun project. Bicycle looks lovely and rides like the wind. 🙂