When in Doubt, Accessorize

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Late 40’s/early 50’s Mercier Meca Dural, as originally acquired – with incorrect 700c wheel size and various missing parts.

To counteract the too frequent headaches and setbacks on the mechanical side of bringing this Mercier Meca Dural back to life, I decided to focus on the “extras” that are often regarded as nonessential accessories – chain guards, lighting, and racks.  As fashion experts know, it’s the extras that really make one’s ensemble come together.

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Baffling chain guard hardware.

Mounting a chain guard, however, proved daunting.  I had a nice aluminum Rigid-branded guard from this same era, which fit well around the 46T Louis Verot chain ring.  But, one of the odd things about this bike is that all the frame mounted braze-ons and brackets are missing.  I had this chain guard hardware set, shown above, that included a baffling assemblage of clamps, threaded bolts, and numerous nuts and washers, but I couldn’t determine how to make this hardware work on this bike and with the Rigid-branded chain guard.

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Creative chain guard mount – spotted in downtown Portland.

Fortunately, while downtown waiting to catch a train a while back, I spotted this wonderful Raleigh Sports with an interesting chain guard mounting solution.  I snapped this photo with my iPhone so that I wouldn’t forget what I saw.  Meanwhile, I searched the internet for chain guard mounting lore.  Velo-Orange came to the rescue, with a nice discussion of different kinds of frame braze-ons for chain guard mounts, as well as how to configure hardware when your frame lacks such mounts.  You’ll note in the photo above that this cyclist has mounted the chain guard using eyebolts on the guard, which make it easy to adjust the chain guard when used with the long threaded bolts – with the threaded portion attaching the the frame clamp.  Using these ideas, I anticipate that I’ll get the Rigid chain guard mounted properly, but I can see that I’ll need a bit more in the way of hardware.

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Luxor 65 headlamp.

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Creases at back of lamp to hold cables in place.

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Very pretty branded Luxor stem clamp.

Moving on to this bike’s lighting system, I re-installed the front Luxor 65 headlamp back on to its Luxor branded stem mounting bracket.  Luxor lighting is very well thought of, and there is even one enthusiast who loves Luxor 65 so much that  the cyclist machined a copper heat sink for their beloved Luxor light so that LED’s could be used with this system.

I don’t plan to go that far, but I am impressed with the quality of this light.  When I was setting it up, I noticed creases at the back of the headlight shell that I thought were caused by the shell being dropped and dented.  But once I had the light mounted, I could see that the creases were in the perfect position to hold the front brake cables in place.  I don’t know if these dents were a fortunate mishap – but it works for me.  You’ll note that I used red cable housing for this build.  These housings are vintage from the 1970’s – they are a darker red than the new red Jaguar cables, and match the dark red color in the Mercier head badge.  Hopefully, the fashion police will agree with my choice.

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Installing the lighting meant coming up with a fork mounted dynamo, which this bike would have originally had (as there is no dynamo mount on the seat stays).  I located a vintage dynamo fork bracket, and installed it on the fork blade over some black cloth handlebar tape, to protect the steel fork.  For now, I have set up this very lightweight and free spinning Soubitez Argil dynamo, which is not from this era, but dates probably to the 1960’s.  If it works well, I’ll keep it.  If not, I’ll source a dynamo from this era.  You’ll see that the fork bracket includes a grounding set screw in the middle of the bracket.  This provides the electrical ground for this system, so it needs to contact the steel fork. But, you don’t want to screw it in too far, as it could damage the fork.

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Finally came the ideas for a rear rack.  I have had this interesting 1940’s steel rack in my shop for awhile.  I haven’t found the right project for it.  I dry mounted the rack on the bike and found that it seemed to fit well.

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This steel rack is reasonably light weight and features fully adjustable stays, so that it should fit on pretty much any configuration.  It is a bit rusted and needs to be cleaned and polished.  It’s not the strongest rack out there, but should work well for this bicycle, which was designed for city riding.

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One of the fun things about this Mercier Meca Dural, is that it served as the inspiration for Public Bike’s Champs-Elyisees d8i bicycle. The above photo provided their inspiration.  When I have completed the restoration of my Mercier Meca Dural, I hope to be equally inspired, and inspiring.

Mercier Meca Dural Restoration Progress

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Restoring vintage bicycles, especially those from the “golden era” which lasted from the 30’s through the 50’s, sounds vaguely romantic and thrilling.  Which it can be.  But the truth is that it can also be a very solemn and tedious process, full of stops and starts.

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This late forties or early fifties Mercier Mecal Dural is one of those projects that can test your resolve.  The bike, whose frame is made from aluminum “duralumin” tubing, was not 100% original, yet the frame itself was in beautiful condition.  Over the course of its life, someone had tried to mount 700c wheels from the 1970’s on this late 40’s/early 50’s bike designed for 650b rims, and had spray-painted over the rust and corrosion on the bike’s original steel fork.  Some parts were missing, such as the original chain guard as well as the bike’s bolt-on attachments for the shifter and chain guard.  And, the Meca Dural head badge was gone.

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Undeterred, I set out to research the history of this method of frame building, as well as to find as many other examples of these frames as possible.  Fortunately, I was successful on both counts.  Several others before me have successfully restored these bicycles, and there is a decent amount of information available on the web and in print which gives a history and background for this interesting frame construction.  However, I still haven’t been able to locate any information on the serial number scheme used by Mercier.  This frame’s SN is 16822.

1953 Mavic rim 650b

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My first task was to find a 650b wheelset from the same era.  I harvested the wheelset from another project, which dates to 1953 and features Mavic aluminum rims laced to Fratelli Brivio hubs.  One of the initial challenges involved rebuilding and restoring the wheelset itself.  While the front hub was easily brought back to its free-spinning glory, the rear hub proved difficult.  I was not able to remove the unbranded 4 speed freewheel from the hub, lacking the particular removal tool.  I modified a Suntour two prong remover, applied copious and various kinds of lubricants to the threads, used both my vise and my giant-sized long-armed wrench, to no avail.  I didn’t want to take this freewheel apart – it is working fine and will probably last another 60 years.  So, that meant cleaning and rebuilding the hub with the freewheel attached.  All went well until I discovered that the original axle was slightly bent. When I was ready for the hub’s final adjustment, I found that the axle could not turn in the hub, due to the zero distance between the hub shell and the cone.  This particular hub has no dust cover, so I couldn’t strong-arm the opening by widening the dustcaps themselves.  That meant trying to find another perfectly straight 9.5mm axle of a similar length and with similar threads.  Amazingly I had ONE such axle in my parts bin – it was only slightly shorter than the original axle.  Whew!  On to the next problem.

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CLB 700 brakes with 650b rims

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CLB 700 brakes with 700c rims

Once I had the wheels rebuilt it became clear that the CLB 700 sidepull calipers were probably not original to the bike.  Their 70cm reach is not quite long enough to engage the 650b rims.  Darn it!  The extra reach needed is only about 2mm.  When there is enough material on the brake calipers to allow for it, you can take a round file and sand the opening lower at the bottom of the caliper arm to allow for a slight improvement in brake reach.  But, these calipers do not have enough material on the lower brake arms to make me comfortable with this approach.  Instead, I will now locate long reach side pulls from this era.  One more setback.

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Tight clearance – chain ring and chain stays

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Stronglight 49D crankset with Louis Verot chainring

Then it came time to rebuild the bottom bracket and install the beautiful, lightweight Stronglight 49D crankset, with its 46T Louis Verot chainring.  Everything went well until I observed the clearance of the chainring to the frame.  I had previously noted what I thought was a crimping mark on the sleeves which serve as the chainstay fender bridge.  When I looked closer, I realized that the “crimping mark” was actually a gouge caused by the chainring contacting the frame at the chainstays, probably under vigorous pedaling.  Investigating further, I found that the chainring itself had a wobble, which is not unusual for this type of crankset with a tiny bolt circle diameter.  A larger diameter can resist stresses from the rider, but the downside is that a larger diameter BCD cannot accept tiny chainrings needed for climbing.

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One of the things I learned in my research about these duralumin frames is that the bottom bracket shell is set up to provide for chain line adjustment.  The shell is a simple aluminum cylinder, held in place with bolts.  In order to address the issue of the crankset contacting the chainstay sleeve under vigorous pedaling, I first measured the torque setting on the bottom bracket bolts, referencing the highest setting at 100 inch pounds as being the most accurate.  After removing the bolts, I twisted the BB shell using the locking on the non drive side of the bottom bracket.  I adjusted the BB shell over about 2mm to provide for additional necessary clearance for the crankset, by taking a mallet and gently tapping the BB.  I would not have known about this option had I not seen numerous examples of other duralumin framesets showing the BB shell in various positions.  Unfortunately one problem with these frames is that the aluminum chain stay sleeves can fail.  I wanted to give this frame a good shot a lasting through the decades, so by adjusting the BB shell, further damage to the chainstay sleeves will be avoided.

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Huret derailleur

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Beautiful Dural Azur stem with arrow design

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Hammered rear light

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Lefol hammered fenders

The next steps involve installing the Huret derailluer and shifter, polishing and cleaning the beautiful components, and setting up the brakeset and cables, and installing the tires, as well as cleaning and lubricating the leather saddle.  Stay tuned for more torture, and related thrills!

650B Conversion Misconceptions

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1980 Meral sport touring frame

A while back I received a hostile diatribe in my comment queue about my Meral 650b conversion.  I spammed the comment, but then thought it was potentially illustrative, albeit rude and obnoxious.   The moron’s comment appears at the end of this post, and because it is full of misconceptions and mythologies couched as “expertise”, I’d like to thank him for inspiring this post.

I purchased my 1980 Meral 700c sport touring frame after researching the ideal geometry and clearance requirements for a wheel size conversion. I consulted Sheldon Brown’s 650B conversion guide, as well as resources available from many other cyclists, mechanics, and frame builders. A particularly easy to read guide is available at Rivendell’s site. Since that time, I have done a number of other wheel size conversions, from 650c to 26 inch, and from 700c to 650c.

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Mafac Raid brakes-to supply adequate reach to the 650B rims.

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Before building up the frame I dry mounted many of the components to check for clearance and chain line.

Those of us who have undertaken 650B conversions understand the brake reach, tire clearance and other considerations that must be explored when contemplating whether to convert a bike to 650B.  My spammer, however, believes that one can alter the geometry of a frame by changing the wheel size.  Without a blow torch, that would not be possible.

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After the conversion to 650B, the bike looks beautiful and eats up the miles.

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Wine cork spacer for the rear fender.

The outer diameter of a 38 mm 650B tire is only a bit smaller than that of a 700c x 20 tire.  The effect of the 650B conversion is to give one a chance to ride on wider tires, making the bike more useful and comfortable, and to provide for fender clearance that didn’t exist with the larger wheel size.  And, as I have stated in past posts, you don’t want to convert a frame to a smaller wheel size if your frame has a lot of bottom bracket drop.  Rivendell recommends no more than 70 mm, but you may be able to get away with a bit more drop if you are using shorter cranks.  Many bicycles from the 1970’s on have way too high bottom brackets to begin with, so lowering the bottom bracket a bit will improve the bike’s handling and cause no negative side effects.

My own Meral has very little bottom bracket drop, so the conversion improved the handling, by dropping the bottom bracket height DOWN to 27.5 cm, still very high, and much higher than recommended by some frame builders.  My trail went from 43 mm to 41, and my wheel flop stayed the same at 12.  The world did not stop spinning due to my audacious acts.  What are the factors at work that cause these changes?

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Rake and Trail, drawing courtesy of Dave Moulton.

When you install smaller diameter wheels, there will be a change in the distance from the center of the axle to the ground, thus reducing the distance of the horizontal line between a straight line following the fork/headtube angle, and a vertical line from the wheel axis to the ground.  Smaller wheel diameter = less trail.  More rake also = less trail, which you can determine from the above drawing by imagining the vertical line through the axis, moving forward, reducing the trail line.  Less trail almost always equals less wheel flop, which can provide improved handling for carrying front end loads.  Wheel flop is a function of head angle and trail, so you can alter wheel flop also by changing to a longer or shorter fork, and/or to a fork with less or more rake.  But in a well thought out 650B conversion, there’s no need to worry about changing the fork.

Another misconception is that a 650B conversion causes fork shimmy.  Even though no one seems to know what does cause shimmy, I think we can say for certain that it is not caused by the “wrong combination of rake, trail and head angle.” which of course a 650B conversion does not affect anyway (rake and head angle being impossible to change without changing the fork).  Fortunately, I eliminated the shimmy on my initial build by using different tires – I switched from the ponderous Panasonic Col de la Vie tires to the comfortable, delightful and fast Loup Loup Pass tires from Compass.

Finally, here is the comment which inspired this post, in full and unedited, with misspellings and grammatical errors intact:

“As you state, the frames is well designed and its construction very well crafted; it was mostly likely built by Francis Quillon the head framebuilder at Meral..and he would be proud of it. However..he designed the bike around 700c wheels and would be astonished that you have fitted 650B, thereby upsetting all the correct design features that he had used in the frames constructions ie head angle, front end clearance, fork rake and trail…all those important features that govern how a bike handles..OH! not forgetting the height of the bracket.
Shimmy is often a result of the wrong combination of fork rake, trail and head angle..compounded, without doubt by using the wrong wheel size. So what you have managed to do is to take a delightful frame that was intended for fast road riding ie sportif use, and try to turn it into a type of randonneur…which it was never designed from the box of frame tubes , lugs etc to be.
As for the massive amount of handlebar stem quill that protrudes dangerously out of the fork column, Quillon would be alarmed at the thought ..and the sight it presents. The least you could do would be to buy one of those elegant Stronglight extra long headset lock-nuts that would both add about 30mms of extra grip to the quill while at the same time making the bike look less ridiculous than it does now…
Never mind the chrome hilights, the wonderful deep purple flamboyant paintwork..you have turned the bike into a travesty of what the designer/framebuilder intended and,
in doing so, insulted his skills.
If you really need so much seat pillar projecting from the seat cluster and such a high riding position, I suggest you get a frame that is more appropriate to your inner leg and body length.
Just a footnote…no French builder, large or small would ever let a bike with toeclip overlap leave their workshop or factory.”

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Shockingly tall seatpost?

This diatribe points out how narrow minded some cyclists are –  adhering to the idea that if they do not personally experience something, then it must not exist.  One of the reasons the seat post and stem are tall is because I am using 160mm cranks, which help to eliminate toe overlap.  Shorter cranks means a taller seat post, which in turn means a taller stem.  And yes, this frame had toe overlap with the larger 700c wheels, and it was indeed designed that way – something that happens when small and even medium sized frames are built around 700c wheels.  Whether the builder considered this a necessary compromise to please a particular customer, we will never know.  Most disturbing about this rant is the ridiculous concept that style trumps comfort when setting up a bike for a particular rider.  Many riders know that taller stems mean more hours of comfortable riding.

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NItto Technomic stem, sanded to French size, a la Sheldon Brown, Shimano 600 French headset.

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A travesty?

Apparently, the original Shimano 600 French headset is an absolute eyesore, when paired to the tall Nitto stem.

So hideous is the bike that it is now a “travesty”.  Well, me and my travesty will see you out on the road.  Happy riding!