Thanks for this useful link. I got my hands on some other bikes with pitted/galled cones. I used the information on the website to refurbish them. I skipped the step with the grinding stone. Here are some pictures from before and after (most of) the grinding was done:






I don’t know yet how the bearings/cones are going to perform, because I just finished doing them. But I put back one hub which I overhauled, test-rode the bike for 1.5-2 hrs on flat surfaces, and the wheel seems to spin okay. On closer inspection I also didn’t notice the problems from before the hub was overhauled.


I wish there were an equivalent way to restore damaged (i.e. pitted/galled) hub bearing cups which cannot be replaced/taken off the hub. The method described at the referenced website is nice as it 1) uses tools commonly accessible in the home shop (from the more 'advanced' tools you basically need a drill); 2) is relatively simple, so the common DIYer can do the whole job without too much trouble and 3) is efficient – the cones come out nice. I realise in case of a pitted/galled cup it’s easier to buy a new wheel or in some cases the hub may be replaced, but there are situations in which neither of the above is possible; plus there are many wheels with damaged bearing cups which are otherwise fully functional (perhaps with the exception of other parts of bearings which on the other hand can be easily replaced/fixed).

Here's a thread on Resurfacing Galled Spindles and Cups. The method deals with bottom bracket bearings and uses a lathe which unfortunately is beyond my reach and, I suppose, it's rather imposible to secure a 26+' wheel to a lathe.

The only thing regarding repairing hub cups that I found on the internet is this:

I think this method could be further improved upon if the cup* is rotated, ideally by a drill (a common tool found nearly in any home shop). This would let one grind off cup races more evenly. Any ideas if it’s possible/how to do it? Also an alternative approach using similar tools wouod also be appreciated. :-)
*in most cases I have to do with, i.e. 90% of the time, I can't take cups out of the hub, which means that the whole wheel has to be rotated.