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  1. #1
    Senior Member custermustache's Avatar
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    Falcon rehab - photos included.

    I am in the process of refurbishing a Falcon San Remo, and I thought I would document the process here for all of my nerd friends.

    When I got the bike, it looked like this.


    You can't see in the pictures, but the paint was terrible - this bike sat out for at least one Texas summer, if not more. there were places where the paint was thin to start with, and it didn't get any better over the years. I took the original mishmash of parts off of the frame and just put on a fixed wheelset and rode it that way. After riding and agonizing for a few months, I decided that this was going to get built up as my "real" road bike, complete with STI shifters and so on. I have a Fuji Ace from about 2003 with some nicer wheels and the Sora stuff on it works great, but the bike doesn't feel like my Falcon does - so I'm going to put those parts on the Falcon.

    After thinking and having a long internal discussion about originality, I decided that I only live once, and it's just a bicycle for goodnes sake. Plus, there is a big tear in one of the stickers that bugs me, so I'm going to refurb it. Cyclomondo has decals for it, so I order the set, make measurements on the frame so I know where to put them back on, and take some detail pictures. I also measure and cold set my rear dropouts to 130. On the way to the powder coater, I dropped by the LBS and had them check my alignment - they tweaked one rear dropout, and I was off to the powdercoater.

    Here is the frame from the powdercoater. The color is a very close match to original, and looks fantastic in person. Unfortunately he managed to chip the coat in the process of taking these photos, so I have to wait while he re-does it. In the meantime, I have these photos

    Whole frame

    Lug detail

    Fork

    I am delayed a week because he is out of that color, but I think that Santa is bringing me the buffer I wanted, so in the meantime, I'm going to be polishing the parts that are going back on.

    Stay tuned for more!
    Last edited by custermustache; 12-22-09 at 08:58 AM. Reason: fix photo

  2. #2
    Senior Member shrinkboy's Avatar
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    looks cool, custer. i look forward to seeing the progress

  3. #3
    Senior Member custermustache's Avatar
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    Thanks. I'm trying to decide wether I want to line the lugs or not.

  4. #4
    Senior Member shrinkboy's Avatar
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    if you have the skill, i'd say line'em

  5. #5
    Seņor Member USAZorro's Avatar
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    Looks like you're going to have a really sweet end result. Going to clear over the decals?
    The search for inner peace continues...

  6. #6
    Senior Member custermustache's Avatar
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    No, I don't think I am - the original just had raw decals on it, so I'm going to just lay them on (carefully). I do plan on buying a second set, just in case I outlive these decals.

  7. #7
    Senior Member custermustache's Avatar
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    Some things have happened, so I thought I'd update a little. My powdercoat job looks good, and the color matches, but he got some powder on the headbadge so I have some cleaning and restoration to do on that. I should have drilled the rivets and put it on after the coat, but I didn't - live and learn. The paint on the badge changed colors and got much darker in the oven as well, so be aware if you are thinking about powdercoating a frame with a badge on it. I got Cyclomondo decals for the bike, and they went on very well using a wet application - well, almost all of them went on well. The top tube decal ended up with a little wrinkle at the seam. I didn't have soapy enough water underneath, so the decal stuck to the frame and got a little stretched. It doesn't look horrible, but I'm not pleased. I ordered a new decal and got it yesterday, so I'm going to document the re-application for those people googling "Cyclomondo decals".

    Well, decals went on cery well, but lug lining was not such a success. I used a paint pen, and it just ended up terrible. It looked nice from 10 feet, but it was so bad that it made me crazy, so they had to come off. I really thought it'd be easier - once again, living and learning.



    As a result, I have spent the past few nights trying to remove the paint from the frame. I thought that a paint pen might not be durable enough to do the lining in the first place, but the paint proved itself to be much more resilient than I thought. Niether mineral spirits or turpentine would remove the paint, so I thought I'd test the rumors about brake fluid and paint - sure enough, that took the paint pen right off of the powdercoat just as easy as you please. I had already spplied the decals to the frame, so I had to be careful not to drip. I very carefully used my best *** show purchase ever.


    I paid a buck for these at a *** show once, and to be honest, I thought I would never use them all - but they have so many uses in a workshop. In this case they were perfect. They were stronger than regular q tips, and allowed me to put a little "Scrub" in my wiping. The brake fluid did not damage the powder at all, so it looks as if my terrible attempt at lug lining never happened.

    I have been polishing silver parts that I am reusing with my new polisher, and things are looking pretty nice. The donor bicycle is completely disassembled, and parts are ready to start going on. It's cold cold cold here in Dallas right now, so the only action for a couple of days might be decal reapplication in my toasty living room. I did pick up a really solid "pro" workstand for an awesome price, so this build is going so much more smoothly then I had hoped.

  8. #8
    Falcon Chaser ricgre's Avatar
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    It is looking good. Sure that was a "San Remo" though? Looks like between 73-75. Did it have the "San Remo" decal or just "Ernie Clements"? Is your frame a single reynolds 26.0 seattube or 27.2 double butted Reynolds?

    Looking forward to seeing the finished product. Hope you get the lining done as that will set it off nice.
    Falcon - Ric
    "Respect your Fellow Collector"

  9. #9
    Senior Member custermustache's Avatar
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    The chainstay decal said - "Designed by Ernie Clements San Remo". Actually I think it's a Super Route 92, according to Sheldon

    I'm going to leave the lug lining off - if I ever meet someone that can do it, I'll have it done, but I don't think my skills are there to make it nice enough.
    Last edited by custermustache; 01-08-10 at 08:41 AM. Reason: spelling

  10. #10
    Senior Member custermustache's Avatar
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    Last night I put the last sticker on the frame, so I thought I'd show you all how it's done. I bought my stickers from Cyclomondo on eBay, and they really are great. I made the mistake of putting the top tube sticker on first, and in the process got a big wrinkle at the seam that I couldn't staighten out, so I had to order a new sticker from New Zealand to fix my mistake. I will say that Cyclomondo makes great stickers, and is a great guy to deal with. The stickers are very robust, in fact they are very hard to remove - it took me quite some time to take the one that I wrinkled off.



    Once removed, though, my frame was ready for re-application. I chose to do the "wet" application again, as I did with the others, so I thought I'd show you how it works.

    First, you have to clean the area with soap and water, then you take your soapy water and re wet the top tube. On the letter that Cyclomondo sends with the decals, he says to use a drop or two of soap in a cup of water - I'd actually recommend using more soap than that, as the more dilute mixture will dry too quickly. That's what messed up my first application.



    Here you can see the soap bubbles on the top tube, waiting for the sticker. Once it's soapy enough, putthe sticker on and carefully align it as you please. Mine went on fairly well this time, and I was able to do a much better job of lining up - the first time I used the more dilute mixture, and the sticker stuck too early. This time I got it aligned as good as I could, and I have no wrinkles, and maybe one bubble that I'll be able to remove with a tiny pinprick - I had to do it on one of the other stickers, and I know it will end up just fine.



    Here is the sticker ont he top tube. If you have sharp eyes you will notice that the stickers are positioned differently from the original stickers. I had to do that because my frame ended up with a chip that needed to be covered by the sticker. I am ordering a second complete set, and I took measurements from the original stickers, so when I reapint (not re-powder) the frame I can put them back in their proper places, should I choose to do so.
    Last edited by custermustache; 01-08-10 at 10:59 AM.

  11. #11
    Unique Vintage Steel cuda2k's Avatar
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    Good looking rig you've got yourself there. Look forward to seeing it (or any of your other quickly growing collection) on the next vintage ride I put together this spring. (and I'm put back together, but that's another matter all together)
    [CENTER][URL="http://VeloBase.com"][IMG]http://velobase.com/App_Themes/VeloBase2_blue/Images/VeloBase2TitleCampagnolo.jpg[/IMG][/URL][/CENTER]
    [CENTER][URL="http://JonPFischer.com"][COLOR="#006400"]Fischer Photography[/COLOR][/URL] - [URL="http://www.bikeforums.net/showthread.php/785462-My-new-modern-quot-Classic-quot-Kirk-JKS-Classic-Terraplane"][COLOR="#8b0000"]Kirk Frameworks JKS-Classic Build Thread[/COLOR][/URL][/CENTER]

  12. #12
    Senior Member custermustache's Avatar
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    Thanks, and I'll be on the next one, I promise. After riding that High Sierra you tested for a while, I ended up buying a larger frame (same model/finish) becasue it was just a hair to small - if you know someone that rides a 19" frame and wants a nice one, put them in touch with me.

  13. #13
    Senior Member
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    Very cool, now you just need a better camera I considered restoring my old Falcon but will probably just keep it as is since it has a pretty nice patina.

  14. #14
    Senior Member custermustache's Avatar
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    I know - these are all Iphone pics. I have a nice camera, but my wife misplaced the memory card. The next group of photos will be nicer.

    If this one had not had such worn paint (and a huge tear in the sticker) then I'd have left it alone, but the finish really bothered me.

  15. #15
    Senior Member custermustache's Avatar
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    The bike in the stand - nearly complete. I took a little time this afternoon to finish up putting this thing together, and because I got complaints I did it with my real camera handy. Sticker detail. I got all of the parts on and took it for a test spin - it rides great, but I'm still doing some fine tuning on the front derailleur - I don't think it's quite positioned right. Ready for a test ride, and once I get it tuned right and positioned correctly, I'll be putting bar tape on. The rear shifts great, but as I said the front needs more tuning.

  16. #16
    Senior Member custermustache's Avatar
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    Original frame paint.



    From the front you can see the lack of paint on the rear stays and the crappy forks.

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