[CR]Making custom bolts ...

(Example: Framebuilding:Technology)

From: Donald Gillies <gillies@cs.ubc.ca>
Date: Mon, 4 Oct 2004 09:14:44 -0700 (PDT)
To: classicrendezvous@bikelist.org
Subject: [CR]Making custom bolts ...

Chris,

I have made much larger bolts similar to your campy pedals bolts for a GB stem. It's pretty involved, but it's also straightforward. just purchase metric bolts with larger heads and longer shaft at any convenient location, for about $2. If possible, get stainless steel, although this is difficult to find in metric sizes, and it's not essential. Also, get a low cost file kit ($10) and a dremel ($20) at kmart. Also, some 600/1500 grit sandpaper ($0.10 / sheet at http://www.caswellplating.com) and some nevr-dull or simichrome is good to have. It also helps immensely to have a drill, which can serve as a mini-lathe for polishing the bolt heads.

Now, you have all the tools necessary to reshape the heads, and cut the bolts to size. Start by grinding down the bolt heads to the correct height, then shrink the flats. The flats are not easy to get parallel and flat, i've found that it works well to cover the theads with duct tape and draw one flat at a time across a file (duct tape is thick enough to keep the bolt head parallel to file, and helps ensure that the _flat_ is truly flat.)

Obviously, the very last step will be to cut the shaft to length and polish it with the dremel. Before you get to the last step, put the bolt into a drill and use the dremel and tiny buffing wheel with white rouge to polish the head to a mirror finish. Then, spray it with wd-40 to protect it (if you will be chroming it), or clean it and wax it (if it's stainless steel.)

When you get done, you can either have the bolts chromed, which should cost about $2, or if you're into it, get a brush chroming set ($25 at http://www.caswellplating.com) and chrome them yourself. Then make sure to wax these parts as all chromed surfaces are subject to rust-through if they are not properly sealed. My 1973 pedals had really badly corroded campy bolt heads.

If you already have the bolts, and yours are just too rusty, then sandpaper (600, 1500, maybe 2000, available at an autoparts store) and a brush chroming set should be sufficient to refinish the to like-new condition.

The benefit is that for $50 tops you now you have all the tools necessary to refinish any rusted steel part on your bicycle. In particular, you can repair pits in the chrome on your forks and stays, or on the head tube, as long as they aren't too big (1" - 2" square is about all the patience I have for such tasks.)

I made about GB 3 bolts, but could never find the weird 10mm x 10mm M8/Wittier nuts, and when somebody listed some used stems with NOS nuts/bolts on ebay, and so i emailed him and ended up buying 3 more nut/bolt sets. Of course, my work is better than NOS GB, and with equal patience you should easily be able to reproduce campy quality for your pedals.

- Don Gillies
San Diego, CA