'63 CA77, or is it?

[Bob750]

Here is a pic of the top of my headstock with the top bearing race installed. I put the race in the freezer for a few hours and used a hair dryer to warm up the hole. It went in without much fuss. What you don't see is the lower bearing race that is installed similarly in the bottom of the tube. That one was harder to tap all the way into place, even with the thermal help. Once those were in, I moved on to the stem...


Here is the steering stem. I slid a new dust seal washer (thin and barely visible in the photo) and rubber dust seal onto the stem first. Then I applied a thin coat of bearing grease to the stem for ease of sliding and corrosion resistance. Then, in the kitchen, I put the lower bearing cone race in a pot of water and brought it to just about boiling. Then I took the pot out to the garage, fished the race out with tongs, dried it with a rag, and slid the race onto the stem. It still took some persuasion with my soft faced hammer to get it all the way down. I suppose it may have been easier if I had put the stem in the freezer.


Once this was done I applied a lot of grease to the cone on the stem and on the dust seal and stuck 19 ball bearings into the grease; I also put some grease into the lower bearing race. Then I slid the stem gently into the headstock all the way, so the dust seal just disappeared into the tube. I then tilted the frame forward to rest on the stem and hold it in place. Then I greased the upper bearing, put in 18 balls, and put the top cone race on. The Steering head top thread turns onto the stem and pulls the bearings tight. Sorry I don't have more pictures of this.

The steering damper parts all sit atop this. Once you have the stem secured with the top thread, place the the steering top plate over the top thread, then slide the "steering damper friction ring" onto the squared steering head stem nut and screw those to the top of the stem, securing the top plate.

I do have some pics of this from disassembly, I will upload those a little later... I'm being called to dinner!

Cheers!

Bob, could you sketch out what you are describing here and post a picture of your sketch. I am traveling on business and all I have to look at is what's in the illustrated manual. I have the races and I believe I have all the ball bearings I need that are in good shape. It's the order of assembly that has me bumfuzzled.

If I'm not mistaken, the lower stem has the curved race on the stem. The bottom of the frame steering tube has the collar (not sure if this is the right term) in it. So, I put 19 ball bearings in the collar held in by grease and slide the steering stem upward into the frame tube. Three parts bottom to top.....race, bearings, collar?

On the top assembly, do any of the steering damper parts intermingle with the order of the top bearings and races. I don't think it does. The shade tree engineer in me says no but, this is my first reassembly and I'm not confident in my assumption. I'll try and sketch out myself and see if I can show what I am talking about.

[primer63]

Thanks, Bob. I think it is as easy as it should be, and am looking forward to your additional pictures.

[Bob750]

Ok Primer, here we go. I took this series as I disassembled my bike, but I've reversed their order, so they'll act as an installation guide.

EDITED to fix problem with linking.

I was going to put all 19 of them in this post. But then I reconsidered... Click this image to get to the album, then click the first pic, then click the LEFT arrow to back up to about #142 of 161. Then you can click forward through the rest. When looking at individual photos, you can use your scroll wheel to zoom in and out like on Google Maps to see better detail. Hope this helps! One caveat: there's a missing image showing a second friction disc. The assembly sequence is: metal-friction-metal-friction-metal.

[primer63]

Ok Primer, here we go. I took this series as I disassembled my bike, but I've reversed their order, so they'll act as an installation guide.

I was going to put all 19 of them in this post. But then I reconsidered... I've linked the first one to my Google photos. So just click this image and then you can slideshow through the rest. Oh, once you're in my album, you can use your scroll wheel to zoom in and out like on Google Maps to see better detail. Hope this helps! One caveat: there's a missing image showing a second friction disc. It goes metal-friction-metal-friction-metal.

Thanks for the post. Unfortunately, your link returns an error code, and I can't see the pictures.

[Bob750]

Fixed previous post. If you get another error, please let me know what the error says.
-Bob

[primer63]

Fixed previous post. If you get another error, please let me know what the error says.
-Bob

Bob, the link to your Google pics worked. Thanks for the clarification on the steering assembly. I am now sure beyond a shadow of a doubt that I am missing some pieces! Particularly the 37 ball bearings. The races are all there. I am missing the plain ring in the set of tabbed ones that fix everything in place on the handle bars, and I am missing one of the locking tabs that fit right under the black adjuster knob. I've got to go back to the parts list and get numbers so I can get them ordered.

Thanks again!

[primer63]

Thanks to some clarification from Bob750 (kudos in prior post) I have the front forks and cushion together now along with the front wheel assembly. My first milestone was to get it to roller status. DONE. Not perfect, just assembled so I know that I have all the parts (or not), and I don't have to keep putting up loose parts after the weekend. My workshop is also my garage which is full of vehicles that need to be out of the sometimes severe Texas weather.

Next step is to order missing parts.

I've been looking at this frame and wheels for almost two years, but I am still struck today by how small these bikes are, now that I have it to "roller" status.