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Old 02-17-17, 05:04 PM   #1
Bikerider007
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81' Shogun 2001- Touring Build

Finally building this. I picked this up mid last year, had saw T-Mar’s Shogun thread and Asian serial number stuff pop up often, so of course I started watching a Shogun that I saw on CL. Basically, this build will be like an ode to T-Mar as he has done so much and helped so many. I had a lot in the queue at the time but knew I eventually wanted at least one Tourer. Problem was, it looked a little beat. But as we always do,I eventually went to take a look and it well exceeded my expectations and it was not nearly as bad as the photo that was taken. So I brought it home for a future build and kept my eyes open regarding touring accessories. Fast forward almost 8 months and I have gathered most needs and wants, and have been working on making a couple items I could not find.


Even though I will never plan to tour the country, or even out of AZ for that matter, I do like to get away and camp and fish. Every so often I spend a weekend just getting away. There is a certain peace and confidence that comes with getting out on your own, so that fits the Touring spirit if nothing else. And since I’m not a poet @T-Mar, the effort will go into the build and I may use some poetic license.

I’ll be retaining the original group (Deore Touring), wheels(Mavic w/AX Aero hubs), bars, etc…..missing; original racks, headset (was upgraded), fenders, clips (changed to black) and water bottle.
As picked up, after a quick wash.

I have already broken down, so I weighed it in,figured I would see what Tange 2001 comes in at. I don’t know which is more accurate. But I weighed in Kilos and that comes out to about 7.12 lbs (3.23 f/f) , but when I weighed in pounds it showed 7.3 (5.16 frame and 1.96 fork). I assume it’s probably in the middle.


Non-original take offs-The AX Aero bottle fits the group and period, but is just too small since there is only 1 holder. Can’t live on beer alone.






Fork-Tange Symbol then "Tange1B"


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Old 02-17-17, 05:18 PM   #2
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Nice bike.

Some touring build thoughts, if you're not trying to go original... I find that style of seatpost tends to wear out and slip. I am a big guy who sets his saddles far back, so it may be me... they're also not very adjustable. Having a reliable, strong, and very adjustable seatpost is important for me in touring. My touring bike has down tube shifters. I have a Trek 620 with bar ends and just don't spend enough time in the drops for them to be that much more convenient than DT's.

My next touring build on a vintage frame will probably have Gevenalle Retroshifters. https://www.cxmagazine.com/retroshif...-levers-review
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Old 02-17-17, 05:20 PM   #3
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Also, don't go bag crazy like I did last tour. I had great deals on Arkel gear and went DC to P'Burgh this summer. Camping gear is so much lighter now and so much more touring is on double track like the C&O towpath that traveling light makes a lot of sense.
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Old 02-17-17, 11:41 PM   #4
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Nice bike.

Some touring build thoughts, if you're not trying to go original... I find that style of seatpost tends to wear out and slip. I am a big guy who sets his saddles far back, so it may be me... they're also not very adjustable. Having a reliable, strong, and very adjustable seatpost is important for me in touring. My touring bike has down tube shifters. I have a Trek 620 with bar ends and just don't spend enough time in the drops for them to be that much more convenient than DT's.

My next touring build on a vintage frame will probably have Gevenalle Retroshifters. https://www.cxmagazine.com/retroshif...-levers-review
Thanks for the info. I'm not familiar with SR posts but will try for now and see. I'm leaving as much as I can original to the bike. I have the correct Shimano headset and will use the Campy one elsewhere as needed. I was thinking barcons as I have some, but want to keep the Deore set together. Those shifters you linked are interesting.

As for bags I had many months to browse and wait. I was ended up with old Cannondale rear panniers,, a bar bag (may use on saddle), handlebar mounted bag, rain covers and the rack from a guy that did a Mexico to Canada ride back in the day. They have a little fade on top and we're dirty from years of sitting (and I assume the rides) but he said he had sprayed (and I will 3m or something as well) so they cleaned up with just the right amount of patina. I won't be doing low riders for the reason you mentioned. I will do no more that 2-3 nights and only need so much room.

I am very far along on the clean up (again months have gone by). Just did not have time to post tonight. I will start putting together tomorrow as well.
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Old 02-18-17, 03:01 PM   #5
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No major issues, but I wanted to clean up some of the larger scrapes and hone my matching skills a bit. I didn’t do every little scratch as the parts have some patina, but the rear triangle is chrome so those scratches really showed through. I did last week and will start putting the bike together today.

A pic of the prep and match materials in order of use.



And a scrape



A little prep after light sanding of the edges of the scrapes and clear coat. Of course I ran out of primer just as I started to spray.



After tape was removed I fine sanded (actually used 0000wool) the primer down

I then hit with the paint over the area to get a blend. The paint was matched from an auto paint shop and is a dark blue pearl/flake. After touching up the stays and a couple spots on the down tube, a clear coat was applied to the entire frame .

The one photo that really showed the cool color is the head, soI’ll start with that.


Frame shot after touch up and clear



The stays



Another angle

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Old 02-18-17, 09:04 PM   #6
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I made good progress but even with all the parts there is a good amount to this one.

Because this is early eighties, it’s not fully loaded like
some of the mid eighties that are more popular, no canti, triple water bottles,or low rider mounts (which I didn’t need but are nice to have).


The thing I did find interesting and want is a spare spoke holder. I read that some taped spare spokes to the chain stay. And in what appeared to be more mid 80’s, the braze-on spoke holder that doubled as a chainstay protector. I don’t really need for that as the stay is chrome in that section, but doesn’t hurt. So I used some hardened plastic ( a Jeep body lift mount) and ground out some pieces to create a spoke holder. I’ll be fastening it around the cable eyelet as the rear positioning point and the fender bridge near the bottom bracket for the front mount. It’s trial and error and took a good amount of time to try and figure out a way to make it work, but appears it may function and will be a nice touch.


I got the fenders lined up but not final mounted. I went with the origninal squared type, they looked like they may give more clearance and reminded me of Bluemels. I thought a little square look may add some dimension as well.


Also, decided I am going to leave the leather bar wrap on,but cover with black cork/foam wrap that I took off another bike. The brown just doesn’t match and is faded, but I think it will make a great padding for under the foam and can always revert.

More pics…..
BB-one key release





Dyna Drive pedal breakdown-28 fun little bearings per pedal. They are set up much like the cones on the wheels. You have to get them set right, I can see why they said some had bearing trouble. If someone that did not know what they were doing tried to adjust it would be just like a wheel. Too tight and they would grind, too loose and they would wear out.





Rebuilt with the straps cleaned up



The Dyna Drive crank going back on.






Original AX "Aero" hubs, broken down and re-greased.




I had the right headset based on a photo of an all original bike (which seem few and far between). I didn’t think I would ever find a use, but this on in place of the campy that came with it is agreat fit for the bike.





There are some nice touches on this bike like the double fork and rear eyelets for mounts, and the solid seat post binder so you don't crack an ear, chain hanger, etc. Was nice to see the fender hole at the chain stay bridge was threaded as well as that works for the fenders and my project.






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Old 02-21-17, 12:15 PM   #7
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Even after all the planning there is much to be done. If this were a race bike I would have been finished Sunday but that's what also makes me excited about what the outcome will be, if I ever get there that is.


A little more done.





Might increase the hole on the side to show the red anno dot. And looking at up close, its not a very clean cut.







Using the paint again, will also do the crank arm and probably the seat post.










Shifters on and lovin the fenders thus far


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Old 02-21-17, 12:27 PM   #8
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That's an interesting bike. I totally forgot about the Deore aero touring groupset, especially the dyna drive touring crankset. That couldn't have lasted more than a couple years. Interesting that there are not lips on the pedals for cleats. I guess they figured tourists didn't wear cleats. Good for a modern recreational rider though.

Anyways, good job on the restoration. Unique bike and it looks great.
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Old 02-24-17, 08:22 PM   #9
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Thanks @Salamandrine


Just some info on the Deore as I haven't had time to do much. The retrogrouch calls it the first Touring Gruppo but it states Ensemble as it does not have a seat post, brakes or hubs (Shimano AX Aero, and 600 brakes came on bike, SR post).


The Retrogrouch: Deore: The First Touring Gruppo






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Old 02-24-17, 08:30 PM   #10
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I mocked up my spoke holder, this is V2. V3 should be it. I need to finalize position and I think I would fab the front piece out of steel vs the hardened plastic.







I had a white Zefal pump with decals that just did not fit any of my bikes. I put some aircraft stripper to it, then polished and cleared it as it was too shiny and would require maintenance. It will go well with the fenders.









I will probably only add the bags when in use, but here they are waiting for me to get my other stuff done. The bags are period correct and came with yellow Eclipse rain covers for the Panniers.



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Old 02-24-17, 08:34 PM   #11
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In this thread I made the straps for the front bag. They work nicely


Tie down straps for handlebar bag.
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Old 02-24-17, 11:44 PM   #12
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Nice bike, I always liked that first-gen Deore touring group.

I haven't seen too many Shogun tourers, this looks like the same series number predecessor to my later 1985 Shogun 2000, when they had moved to cantis, a later Deore group (deerhead / xt) and added more of the later full touring braze-ons (three bottle cages, front low rider mounts etc).



A few more detail pictures here: 1985 Shogun 2000 touring bike - Album on Imgur

That fork on yours looks familiar too, I think the mid-80s Schwinn Passage touring bike had the same Tange 1b fork.
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Old 02-25-17, 06:42 AM   #13
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Nice bike as well @mainstreetexile the mid 80s produced some loaded bikes. The retrogrouch does a great job of compiling Tourer info from the 80s here. The Retrogrouch: Just Add Bags it shows the Miyata, Centurion, Schwinn, Shogun, Bridgestone and Trek models.

I also found it interesting, although I don't know first hand, that he notes (referring to the early 80s) " In a lot of ways, touring bikes were perhaps more popular than racers. Of course, in the '70s there was less of a difference between the two, as racing bikes back then had much longer wheelbases and more tire clearance than they do now."

It's tough to compare bikes side by side, especially when hand made as many racers are, but I had a feeling 80s seemed to be more refined for the racers. But I have also seen others comment 70s had more agressive geometry.


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Old 02-25-17, 07:47 AM   #14
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Very nice! I've become a huge fan of 80s touring bikes since rebuilding my '84 Centurion Elite GT 15. I love the attention to detail you're putting in to this. I can't wait to see it all finished up! Nice work
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Old 02-26-17, 10:09 PM   #15
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Thanks @AustinFitz. Trying to keep mostly original and period correct as much as possible, but also make it fit for me.

I finally....finally, got my spoke mount/c stay protector made. Almost got electrocuted in the process but it works well.

Probably would have been the first time someone was shocked that way, but my derailleur cable was hanging from the shifters as I had not connected at the derailleur. I had an extension cord that had a couple things plugged in. One was a light I was dragging around. Well right where the cord plugged into the extension cord, the cable fell across the cord and slipped right between the light plug in and extension cord. The plug was not pushed all the way in, due to dragging it around. Sparks flew and then darkness. I blew the breaker. I was holding the bike but had a glove on or might have got a little zap.

Made the mount out of strap and used the cable guide to help hold it in place. Had to keep it out of the way of the derailleur cable. Will shape the ends later.



Cut the front section out of 3/8 steel, over kill but what I had on hand. I've made trusses, ladder bars etc for Jeeps. A great way to save money on steel is go to a local steel supply house, ask to go through their scrap pile and it's much cheaper. Anyway, drilled the holes at an angle as the stay tapers out. Screwed in the fender, slid the mount in front of the bridge and put a nut and lock washer in place. Not sure I like it red but won't know til further along. And can make it a little smaller and round a little more, maybe later.



Shaped and drilled a piece of composite hardened plastic for the rear. I needed something I could put very small screws in to hold the strap in place and tapered it up for the spoke holes. Used a little piece of foam bar tape under to help tighten and not scratch the bike. I did the same up front where the steel lays on the frame.



Done! It took some time to fine tune the versions, shapes and placement. I had to make sure I would get no chain rub even in crossover and on the smallest ring. Also, had to watch the small ring and derailleur in the front. I had doubts but was able to get it aligned and it works well.


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Old 02-27-17, 10:27 PM   #16
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This thing is almost there. Some tuning and tightening, then it's time for racks and bags. The non drive side is the favorite of all my bikes, hands down. There is something about the aero hub, brake pads, and metal I dig. I could see a single speed in this color and set up. I had planned on more red but it was looking gaudy and not in a good way. So glad I took my time and made the right call.

A quick shot.



I added the old computer from this thread Vintage Cycling computers-KWH Ciclomaster I think the thickness just looks ridiculously cool. Cannot wait to get this on the road.

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Old 02-27-17, 11:25 PM   #17
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Quote:
Originally Posted by Bikerider007 View Post
I also found it interesting, although I don't know first hand, that he notes (referring to the early 80s) " In a lot of ways, touring bikes were perhaps more popular than racers. Of course, in the '70s there was less of a difference between the two, as racing bikes back then had much longer wheelbases and more tire clearance than they do now."
Touring bikes were a big thing if not the big thing from the mid 70s to the early 80s, IIRC. Yeah, more popular than racers with the general population, even though most people that bought them didn't actually tour. When mountain bikes came out, they gradually took over, pushing out the touring bikes.

My late 60s PX10 'racer' has virtually identical geometry to a touring bike. 45cm chainstays, 72 parallel HT and ST, and in fact I set it up as a touring bike. My understanding is that pro races involved riding on a lot of unpaved road sections then.

Back more OT: I'm digging that chain protector spoke holder thing you made, and the bike shaped up really well. Aero hubs are funny. I'm not sure how they were supposed to be aero, but they did look cool and still do.
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Old 02-28-17, 06:26 AM   #18
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@Salamandrine thanks man, that spoke holder took some thought and fanagling. It felt good to get that right as I was not sure I would scrap the idea. I could not find any homemade online as a reference so the back mount was the puzzle. My goals were for it to stable and have no permanent effect, or I would have canned the project.

I thought it was funny they matched aero hubs to a Tourer! They will offset the square bags. Haha. I just assume they wanted to match something different to the new Touring group and figured, hey why not the new Aero?

The little caps would be great in aluminum but they kind of pop in. I guess the Aero is that they cover the nut and get close to the frame, the spokes also appear countersunk a little more. Any difference? I have zero clue, but you know the era well, it seems Aero was the thing in the early 80s+ so everyone was experimenting.

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Old 02-28-17, 06:33 AM   #19
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Originally Posted by Bikerider007 View Post
I mocked up my spoke holder, this is V2. V3 should be it. I need to finalize position and I think I would fab the front piece out of steel vs the hardened plastic.







I had a white Zefal pump with decals that just did not fit any of my bikes. I put some aircraft stripper to it, then polished and cleared it as it was too shiny and would require maintenance. It will go well with the fenders.









I will probably only add the bags when in use, but here they are waiting for me to get my other stuff done. The bags are period correct and came with yellow Eclipse rain covers for the Panniers.


Those are great bags.
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Old 02-28-17, 09:01 AM   #20
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@himespau they have some wear but got them local with an old Trek rack and they are a great fit for it.

I didn't pull the Mathauser pads as they look Shogunish to me. I did have one other take off. A Rhode Gear flickstand. Funny, but I believe this did not help the bike sell. The seller had a pic that was not good and it appeared paint was missing or decal was scraped off. When I got there I saw the flickstand on the down tube and realized condition was not bad. I want to leave on and considered making a sliding 3" or so hole in the front fender but will have to see. I'm debating cutting the fenders but it may help when bike is loaded and leaning. Or maybe it's time for a kickstand. Did I just say that.



It got late last night and is still raining but I need to close this out. Final stuff, saddle is an older Kashimax Japan. Tires are Paselas and although it's not why I added them, they are stamped Japan. Bike karma. Ha!

All but done and final pics. Its raining so indoor pics and that's unfortunate as the color in the sun is nice. I have not seen these on my computer, but they look fine on my phone.

Unloaded







With bags and pump.



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