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Old 05-25-11, 02:53 PM   #1
The MAX
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Help with repairing a Sunshine hub?

I'm pretty close to finishing the overhaul on a 1983 Raleigh Condor.


(before pic)

Nothing fancy like new paint or anything. Just a new cartridge BB to replace the old one, and cleaned and regreased everything.

I'm having some trouble with the rear wheel. I've taken apart and repacked a few wheels now for restores, and this is the first time I've had an issue. The cone on the drive side of the rear wheel has a little pit along the bearing race. Upon repacking and doing the hub adjustment I could not get the sweet spot. It was either too sloppy, or it was grinding just enough to not be okay. I attributed this to the small bad spot on the one cone. Now, I have been reusing old bearings in some of the old bikes after inspecting them to make sure they were in okay condition.

Anyway, I decide to head to my local bike co-op to see if I can't find a suitable replacement cone. However I can't get anything to thread onto the axle. So either they're all stripped or I have something funky going on with my axle.

And now I don't know where to go from here.

I'm not really sure what the deal is with cones/hubs. Are specific cones matched to hubs? or can you use anything as long you make sure the spacing is the same so you don't have to redish?

Buy a new cone/axle and/or new bearings? Suck it up and buy new (used) 27" or try and fit 700c wheels?

Any help would be appreciated.
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Old 05-25-11, 07:57 PM   #2
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I don't have anything useful to add, except that:

1. That is an extremely beautiful bicycle. I really like that and wish I could find one like it.
2. Sunshine hubs are well made. I'd do my best to save it. The hubs on that bicycle are probably something like Pro-Am's, which I adore.

I'm not much help on the threading issue. Campy cones may work.
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Old 05-25-11, 08:10 PM   #3
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IIRC, there are 2 different threading standards commonly used for the axles, so that might explain why none of the replacement cones worked. About 2 years ago I was able to find replacement cones for my Sunshine/Sansin hubs at my LBS, so they are available. If you can't find a replacement cone, then you can get a replacement axle with cones set.
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Old 05-25-11, 08:15 PM   #4
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I suggest you buy new bearings for both sides and install. I would also look at the pit with an eye loupe or magnifying lens. If there are any sharp edges, I would gently polish with a dremel tool, keyword is gently, you just want to knockoff a sharp edge. After a light polish, I would move that cone to the nondrive side (less load). I would also suggest a good quality grease. Adjust the cones with just a tich of play, as when the quick release is tightened it makes a slight change in the adjustment.
I've used this method on many older hubs that I was too cheap to replace the cones, the gentle polish with the dremel really helps and definitely use new bearings. Let us know how it works.
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Old 05-25-11, 08:30 PM   #5
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This 'is' one beautiful bike! I'd put the same question on the mechanics forum if I were you. Although there are better C&V specific mechanics on this forum, they don't seem to appear very often. Maybe they are too busy working on bikes. I just went through a similar experience and will tell you what I 'think' I know. I just rebuilt a wheelset form a '79 bike that had a broken axle and one pitted cone on both the front and rear. The hub cups were fine thankfully. I initially thought that the cone shape i.e. angle of the curve had to match the size of the bearings, but apparently they don't. It does make a difference in the thickness of the tip of the cone as it has to allow enough room for the bearings. Some are thicker then others. I also found out about the differences in axle threading. By going to every LBS in my area, I was able to piece together 2 new axles and cones. The cones were especially hard to find because the bearing on my hubs are 1/4" which is much larger than most. Many cones I tried were just to thick at the tip to allow enough room for the bearings when tightened down.

So, I wouldn't give up yet. I think this bike deserves new bearings and cones if the cups are smooth.
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Old 05-26-11, 07:00 AM   #6
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Beautiful Bike! I would try to buy new bearings and new cones. I would only try to polish out cone pitting on a dept store bike or a bike I really didn't care about. If the bearings are at all discolored they are bad, they are also cheap so why not buy new ones.
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Old 05-26-11, 11:26 AM   #7
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Every hub manufacturer makes there cones different sizes. I have a Sutherland's at home that list them (someone recently posted a page from an online source). Sutherland's
has a list of cone threading and I think cone sizes (front to back and diameter). I have box of old axles with cones and some NOS. PM me if you want more info.
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Old 05-26-11, 08:45 PM   #8
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I did look in my Sutherland's. List Japanese rear hollow axes as 10x1mm. Same as Campy. Does say much about the cone sizes.
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Old 05-26-11, 09:07 PM   #9
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I knew I've seen a chart with lots of different size cones. Modern - so probably doesn't cover Sunshine.

http://wheelsmfg.com/tech/PDF/wheels_cone_chart.pdf

More here:
http://wheelsmfg.com/tech/PDF/hub_cone_chart.pdf
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Old 05-26-11, 09:20 PM   #10
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Good stuff Bikemore! The question I would have is how to pick the right one from all those choices to match a particular bearing size. I guess you have to have a micrometer to measure the old. I ended up taking my pitted one around to every parts bin in my area and trying to match by eyeball the length and cone shape the best I could. I'm pleased with the adjustment I achieved with the ones I found.
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Old 05-27-11, 01:28 PM   #11
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Are Sanshin, Sunshine and Suntour hubs more or less the same?

Loose Screws, www.loosescrews.com sometimes has suntour or sanshin cones.
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