how to build a bike?

My girlfriend has an old ten-speed (late 70's Puch) that I decided to fix up for her, using mostly parts I already have. Problem is, I don't really know how to start. 

[Before you encourage West Town Bikes, be aware that I work on Tuesday and Wednesday nights and Saturdays, so scheduling-wise that's out.]

Can anyone recommend a book (preferably with lots of graphics) about basic bike maintenance or building?

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Permalink Reply by Duppie on January 20, 2010 at 10:18am
West Town Bikes (yeah, I know) runs a 8 week long build-a-bike class on Thursdays. Luck will have it that a new series starts tomorrow. The class teaches you how to maintain all major parts of a bicycle.
I would confirm with Alex, but it sounds that your bike might be a good candidate for an project bike

I did the class last fall. Not cheap per se, but worth every penny! If you have no experience yet in maintaining bike, I'd say this is an excellent place to start
Permalink Reply by on2wheels on January 20, 2010 at 10:38am
My advise is, if you have the time, patience and organizational skills - make this a learing experience.

- Take the bike apart, as far as you dare - ask LBS to help with special tools, either buy or have them loosen
- Carefully record what you take off, what order it goes in and where
- clean, degrease and dry everything
- Re-grease and re-assemble according to previous notes
- Replace parts where necessary
- Make adjustments and take to LBS for a verification

Remember - bikes are pretty simple and very forgiving and you have a huge base of knowledge here and elsewhere on the internet.
Permalink Reply by pjc jr on January 20, 2010 at 10:44am
Yeah, the hands on training is really helpful! And access to all the specific tools is worth the investment alone!

Back in the day I purchased "Zimm & the art of Bike Maintance", great pictures and good general info that covers a range of bikes. But as much as it was a terrific reference, I still had to go out and purchase a lot of tools over time which I am very pleased I have. But it was quite a long term monitary investment. Also, more and more videos are appearing on the web that will walk you through a repair or un/install steps.

Lastly, if you get stuck, there are open shop nights to go to and get help or access to tools. And of course you will always receive a great deal of help just asking on Chainlink!

Good Luck!
Permalink Reply by jen on January 20, 2010 at 11:00am
get the book Glenn's complete bicycle manual by Harold T. Glenn. Its amazing and will take you step by step with lots of pictures
Permalink Reply by Barry Niel Stuart on January 20, 2010 at 11:20am
When I had to replace a crashed frame on a "94 Schwinn Passage road bike with a "97 frameset, I took the parts off in order from the outside in, starting with wheels, racks, bars & stem, seat post,, eventually working tothe bottom bracket. Then I started with the bottom bracket and worked outward. Because the new frame's clearances were tighter and sportier, I needed to use narrower tires, 700c x 25 instead of the 700c x 28 tires I was previously using. Also,that frame had no room for fenders.
Permalink Reply by Ed on January 20, 2010 at 12:25pm
Parks Tools' "Big Blue Book of Bicycle Repair" covers a lot. I bought at the LBS for about $25.
Permalink Reply by RodimusPrime on January 20, 2010 at 12:32pm
park Tool basic bicycling in maintenance or something like that. . big blue book.

get in cool with a bike shop, and ask for advice
Permalink Reply by mike w. on January 20, 2010 at 12:59pm
Richard Ballantine's "Richards Bicycle Book" was my bible. Later editions were "Richards New Bicycle Book." Good drawings & diagrams, fun political rants and lots of opinionating... a good read.

i believe the original was circa 1972 or so. Any bike manual from the '70's would probably be good for your friend's Puch. If my local library is any indicator, you ought to be able to find any of these relics at your local branch library. Also try used bookshops when you have time to browse.

Good hunting!
Permalink Reply by nhylc on January 20, 2010 at 1:32pm
dig it...

mike w. said:
Richard Ballantine's "Richards Bicycle Book" was my bible. Later editions were "Richards New Bicycle Book." Good drawings & diagrams, fun political rants and lots of opinionating... a good read.

i believe the original was circa 1972 or so. Any bike manual from the '70's would probably be good for your friend's Puch. If my local library is any indicator, you ought to be able to find any of these relics at your local branch library. Also try used bookshops when you have time to browse.

Good hunting!
Permalink Reply by Lee Diamond on January 20, 2010 at 3:31pm
Join Bike Builders and then come out for Bike Building Mondays!
Permalink Reply by A.K.A Paul on January 20, 2010 at 5:05pm
Im taking the fulltune course that just started last Sunday at Rapid Transit. Via the course you will completely overhaul your bike. This past Sunday we did headsets. If you jump in now, you'll be able to do the rest of the bike and I can show you how to do the headset, or they are pretty cool there so if you asked, they would probably show you how to do the headset before one of the other classes if you show up early.
The class also comes with tha Big Blue Book of Bicycle Repair from Park Tools.

Paul
Permalink Reply by Green Machine Cycles on January 20, 2010 at 5:32pm
The books people have mentioned are good starts, but there's really no substitute for hands-on learning, as many people have said. The very best of the best things is to have a really experienced friend (or acquaintance you can pay off with beer or food) look over your shoulder as you tear bearings apart and so forth, so you can have a running commentary on what to look for as you work.

If you don't need to replace worn or missing parts, your task is quite a bit easier than if you do need to do so. Replacing parts on older bikes requires a level of observation, skill, and experience best left to someone who has worked in a good shop for at least 5 years or so. Many modern parts do not exactly conform to the specifications of vintage ones (like bottom bracket spindles, hub cones, brake arches, freewheels, etc.) and often a modern part, or the components to which it attaches on the bike, will need to be accurately modified in order to function.

It's probably best to leave wheel truing, frame alignment, and final brake adjustment to someone who's done these things dozens of times, mostly for safety's sake. That said, there's little more satisfying than overhauling your bike and feeling the enormous difference the work you did had on the ride quality.

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