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1985 Trek 620 Build: A Unique Bike For My Old Man

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1985 Trek 620 Build: A Unique Bike For My Old Man

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Old 09-21-11, 02:53 PM
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Amazing build continues. Love the images.

I'm stunned by how long the rear stays are, thus requiring that extra long spacer. I'm used to struggling to get a rear wheel in w/o deflating the tire. That sure won't be a problem here. This is almost to a utility frame with that back end.

What was the stack height on your fork. That Grand Cru headset needs, at least, 41mm. Correct?

Great stuff, as always!

Owen
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Old 09-21-11, 03:06 PM
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Originally Posted by ColonelJLloyd
It is a Tange crown/steerer. So you suggest starting from the crown? My inclination was to start from the dropout as the hole in the crown is about twice the diameter of the vent hole in the fork crown. What'd you use for a tracer wire? I was thinking about a guitar string.

I hope I can make it happen; I'll give it my best.
Yes, from the bottom up. A guitar string might work. I found that a derailleur cable was too stiff, and some narrow gauge electrical wire wasn't stiff enough. I ended up using single-strand picture hanging wire. But nothing could negotiate the exit at the crown. Apparently where the fork blade meets the top of the crown there was just a very narrow gap allowing the wire to pass through before reaching the vent hole, so you're basically trying to snake the wire past two separate obstacles. The wire kept getting hung up there. I also tried feeding thread through and using suction from a vacuum hose at the steerer, and that didn't work either, as the thread would continue to get sucked into the fork blade at the bottom, but get all bunched up somewhere inside. The winning trick was to glue a short, 3" length of thread to the end of the picture wire (as suggested by a bikeforums member). Then insert the wire as before until it gets hung up at the crown. Then use the vacuum to suck the thread out the vent hole. With some gentle pulling on the thread, I got the picture wire tracer through. Then I just soldered some of the electrical wire to the hanger and pulled it back through the other way.
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Old 09-21-11, 03:14 PM
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Looking good! Your pop is going to be pleased.
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Old 09-21-11, 03:15 PM
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Anton,

Did you widen the existing holes at all?
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Old 09-21-11, 06:47 PM
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Originally Posted by fender1
Anton,

Did you widen the existing holes at all?
Nope, used the vent holes as-is. I wanted to drill them out and eyelet them, but the frame builder didn't like the idea of removing metal from a fork blade. This is how it worked out (sorry Justin for going O/T):

In through the fork blade vent hole:


Out through the fork crown vent hole and down the steerer:


The wire is single-conductor wire, which I later swapped out for dual-conductor wire when I decided I didn't want to use the frame as common ground.
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Old 09-21-11, 09:40 PM
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Originally Posted by southpawboston
Nope, used the vent holes as-is. I wanted to drill them out and eyelet them, but the frame builder didn't like the idea of removing metal from a fork blade. This is how it worked out (sorry Justin for going O/T):
Off topic? Off topic?! No way, man. This is so helpful! You're right, Anton. Your Shogun's fork looks just like this one save the double eyelets. I'm going to a remove the brakes and the fork and give it a go. There's still a lot to be done (wheel build, hook up the brakes and derailleurs, front fender install, rear rack, etc).

Originally Posted by LeicaLad
I'm stunned by how long the rear stays are, thus requiring that extra long spacer. I'm used to struggling to get a rear wheel in w/o deflating the tire. That sure won't be a problem here. This is almost to a utility frame with that back end.

What was the stack height on your fork. That Grand Cru headset needs, at least, 41mm. Correct?

Great stuff, as always!

Owen
Thanks, Owen.

Right. Longest stays I've seen . I've not measured the stack height of the fork. I wasn't expecting the VO headset would require a spacer here, but I'm very hesitant to cut the fork.
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Last edited by ColonelJLloyd; 09-21-11 at 09:51 PM.
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Old 09-22-11, 07:28 AM
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Salutes Colonel. Great project. Just wish you'd quit referring to your dad as "the old man". Familiar colloquialism, of course, but I feel aged when you say that. ...you whippersnapper, you.
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Old 09-22-11, 10:33 AM
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Lookin' good!

Similar to what I did for my dad... https://www.youtube.com/watch?v=buOqyhNESu0
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Old 09-22-11, 12:39 PM
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I remember the thread you started about that bike, Standalone. That's a fantastic build. Very nice. I actually have a '72 Grand Prix; my FG/SS frame.
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Old 10-19-11, 10:30 AM
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I've made some progress and changed a few things.

The wheels are built. The front is a Sanyo dynamo/Sapim DB SS/polished CR-18, but will probably be moved to my mother's bike because I just bought an SRAM i-Light dynamo and two more polished CR-18s. The rear wheel is a VO Grand Cru Touring hub/Sapim DB SS/polished CR-18. Mom's bike will get a SA XRF-5(W).

The Soma Oxford was a pleasant surprise. While it is slightly narrower than the Nitto Albatross, all of the other features are there. It has the same bend and it DOES accept bar end shiftes (the ends are drilled out) and it costs a LOT less.

Sorry for the bump without any good pics, but I should have some this evening.

I am seriously thinking about taking fender1's suggestion and returning to my powdercoater with the Dajia Expedition rear and VO Pass Hunter front rack and having him coat them to match the bike. My dad doesn't have to have a front rack, but the fact that it adds another fender mounting point is a big plus in my book and it's also a better point to mount the headlight. If I do this I won't go to the trouble of trying to route the wire through the fork (I've not been looking forward to that).









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Old 10-19-11, 11:15 AM
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That's a nice comparison, Justin. Photos like this do a lot more for the visual approximation of the shape of the bars than mere measurements and dimensions.
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Old 11-05-11, 10:38 AM
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It's done. Finally. I'm very pleased; I think it's my coolest build yet. Most importantly, my dad is really stoked. He loves it. We went on a 17 mile ride yesterday and everything worked great. He loves the handlebar setup.

Lots of cool bits including a Sanyo dynamo hub and Lumotec IQ Cyo Senso R light, powdercoated VO and Dajia racks, 8sp Ultegra indexed drivetrain and VO sealed bearing BB, touring hub and pedals.



















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Old 11-05-11, 10:48 AM
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Outstanding!!!

Cheers,
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Old 11-05-11, 10:49 AM
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Great work, Justin. Those coated racks look real good. A nice change from the usual chrome or polished units. Hopefully, your Pop puts it to a lot of use.
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Old 11-05-11, 10:56 AM
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****, wow man that is totally awesome.
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Old 11-05-11, 10:59 AM
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Originally Posted by Zaphod Beeblebrox
****, wow man that is totally awesome.
+1

What are the black nubs protruding from the handle bars?
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Old 11-05-11, 11:03 AM
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Thanks, dudes!

Originally Posted by tugrul
+1

What are the black nubs protruding from the handle bars?
Tugrul, those are nubs usually used for a tandem stoker's drop bars. I found myself putting my hands there a lot when I used Albatross bars so I thought these were a good idea. They only come with clamps for 23.8mm bars, though, so I robbed some clamps from some cheap townie levers. They're nice for climbing and sprinting or just when you need to stretch your back.

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Old 11-05-11, 11:06 AM
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the detail work is great man. You really put a lot of thinking (and drinking) into this one!

inceidentally this frame has my favorite feature that I really want on a bike of mine someday....lugged fastback seatstays. mmmmmmm



oohhhhhh yeah.
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Old 11-05-11, 11:10 AM
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Yeah, I think this was the first year for their investment cast lugs. The hanger is original to my 1988 Voyageur.

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Old 11-05-11, 11:17 AM
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Well thought out, functional and beautiful , what more can you ask of a bike? I'm sure you're dad is impressed.

Are you an only child?
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Old 11-05-11, 11:20 AM
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There is no doubt you must really love your dad. Elegant, functional, well planned & executed. Really beautiful work!
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Old 11-05-11, 11:40 AM
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Beautiful bike and a truly fine craftsmanship. I've put those silver cables on my Saga build. I tried to buy the oxford bars a few months ago and VO was out of stock. I'll bet you got the last pair.

I ended up getting the Soma Sparrow 56 bars.

Again. That's a stunning bike.

Last edited by gitarzan; 11-05-11 at 11:47 AM.
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Old 11-05-11, 11:41 AM
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Originally Posted by -holiday76
Well thought out, functional and beautiful , what more can you ask of a bike? I'm sure you're dad is impressed.

Are you an only child?
Nope. My sister is five years younger.

Thanks for all the compliments. I thought about what I would want in a bike if I could only have one. This can pretty much do it all. Were it my only bike I'd probably have put drop bars on it, but dad really liked the Albatross bars I had on my tourer for a while.

Yep, I love the old guy. He's pretty alright.

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Last edited by ColonelJLloyd; 11-06-11 at 08:03 AM.
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Old 11-05-11, 12:01 PM
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Fabulous build, Justin. Great attention to the small details that count.

The best part has got to be riding with the Dad.

1000% cool.

Thanks for the fabulous photos, to boot.

Owen
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Old 11-05-11, 12:36 PM
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Super nice build!

The detail is wonderful

Ridding with your Dad, priceless!!!
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