saving a 90s cannondale - vintage road bike build & restoration
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- čas přidán 6. 06. 2024
- here i pick up an old 1997 cannondale caad2 r300 and work on it to make it new(ish) again. some tips and tricks along the way, cheers!
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running time: 1hr and 42 seconds
00:00 intro
00:32 bike check
03:32 bike breakdown
08:46 stuck bb
10:46 cleaning frame
11:30 t cut
11:58 diy headset remover tool
14:23 cleaning bottle bosses
16:13 exage sport groupset
17:19 fixing sti shifters
19:32 downtube shifters mod
21:05 cleaning rusty headset
24:15 diy headset cup install tool
25:06 installing headset
25:59 how to work out tyre size
27:48 cleaning parts
31:17 fixing bent hanger
32:51 cleaning parts 2
35:15 diy bar shim
37:18 installing brake levers
38:13 cleaning bb
38:33 installing bb
39:10 installing cranks
39:49 installing shifters
40:14 installing brakes
40:33 installing rear d
41:00 installing front d
41:30 cleaning & servicing wheels
45:02 installing housing
46:02 installing brake cables
47:48 wrapping bar tape
51:34 installing seatpost & saddle
53:00 installing gear cables
53:26 setting limit screws
54:51 installing chain
57:00 dishing wheel
57:32 final bike
58:44 ride
59:59 outro - Jak na to + styl
Nice clean result, great work! All the best Andy
Wow thank you so much !!! Love your videos I learnt my t-cut (& lots more) from you !! You’re pro!! Thank you for all your videos 🙏🙏😊😊
You've brought that bike back just enough, without taking the true charm of why we all wanted one like this when we were young nice work Gary😊
Cheers Rory! Haha yea soemtimes it’s nice to keep it classic 🙏😊
The exposed Asahi can is the best part.
Hahaha yessss I like it too
Excellent restoration and assembly! It's keeping history alive. Reviving a vintage road bike is a fascinating thing these days. Here in Brazil, we have one that is a cultural icon called: Caloi 10. In the 1970s and 1980s, it was the dream of many. Greetings from this Brazilian vintage road bike enthusiast.
Thank you I appreciate that ! Yes good to be able to save a classic frame. Ooo that sounds like a cool bike. Greetings from Melbourne australia!
Love restorations like this. Keeping most of the original parts 👍
Cheers mate! Sometimes got to keep it OG
Been watching this channel for about a year now. This was an awesome build!! I appreciate how you use ingenuity over cash to get it done! You're a clever Man!
Cheers Jon ! I appreciate that , thank you for being a longtime supporter 🙏😊
Dream bike resurrected, there should be a sainthood in this for you Gary. A short on how the two of you are getting along would great if you get the chance. Thanks for sharing👍
hahaha classic! That would be amazing. Thanks for watching and the kind words cheers!! 🙏😊
Absolutely brilliant!!; many thanks Sir for posting; I have just started on the "Classic Bike" resto journey; your tutorial is invaluable !!!
Thank you very much I appreciate that ! Best of luck with your project!
Thanks for the great work! Can’t wait to see your next project!
Wow !! Thank you for your generous donation William I will use it towards the next build ! Thank you so much !! 🙏💕💕💕
May I ask what camera and lens are you using for filming video? And usually how many days did you use to work on one project?
Yea of course ! I use iPhone Xs Pro, it’s from a few years ago but I use it for everything. Works quite well! Usually for restorations it takes me about 2 weeks to 1 month , but a lot of the time is waiting or sourcing parts. Hope that helps cheers !
Nice job! I've had bikes just like it that were in rough shape from being left out in the rain for a few years, but a little elbow grease and patience makes all the difference. Now that Cannondale is a beautiful bike. One of the best bike restoration videos ever!
Hell ya sometimes they just need a bit of love and they are back to life ! Cheers mate I appreciate that 🙏
Long live that chain breaker!
Hahaha it goes hard, actually works better with the screwdriver lever
thanks Gary, another great bike rescue, love the dark green frame, spot on
Cheers Reece! Loving the color too , not too out there but has a bit of style!
Great to see some renewed love for retro roadies, especially now that you have your whole process figured out. It was a lovely sunday afternoon chillout watch !
That green paint is really nice in the right light, shame about the deep corrosion...
Glad you liked it! Ya shame about the corrision , maybe I will sand down at some point. Still, happy I saved it 😂
And all this time using a screwdriver to take the head set cups off! Best diy tool on CZcams. Thanks a lot!
Hahah no worries hope it helps! Cheers 😊
Nice touch with the down tube levers! I'd recommend Vintage Velos to you and anyone who loves watching these beautiful restorations.
Cheers mate! Thx for sharing 😊
The excitement level peaked when it came to that fluted seat post and turbo saddle 😍 . Looks banging mate. Keep up the excellent work 😎
Hahah cheers man yeah I was stoked when I got the seat post too, took forever to arrive ! Looks slick though , cheers!
Excellent video, I’m getting ready to restore an ‘86 Specialized Sirrus once I retire. I’ve got it rideable and dialed in. It was headed to the scrap yard before I intervened and snatched it up. It’s all original but I’ll tear it down and repaint the frame, stem, handlebars. Has great wheels and original down tube shifter drivetrain and brakes. Thanks for a great video.
Thank you I appreciate that ! That sounds like a great bike to restore. Have fun with it , cheers !!
Great result as always! Nice work Gary!! 🙌🏻
Cheers Ysh i appreciate that ! 🙏😊
Nice build, love the old Made in USA Cannondales. Downtube shifter work becoming a lost art.
Cheers! Ya I love the old cannondales too, also downtube shifters make the cockpit cleaner ✨
DIY handlebar shim looks great!
Thanks mate !
This is a beauty, so good to see such a nice bike back on the road after sitting out in someones garden for ages. Great work mate
Thank you Nick I appreciate that ! It’s good to get it running again for sure. 👍
beautiful build! been waiting for you to do another road bike for ages and you've produced a masterpiece. keen to see what you serve up next!
Cheers mate ! Sorry for the long wait , I got stuck into mtbs for a while 😅😅😅 nice to do a roadie again !
A flipping great build mate .... Looks great. Well done.
Thank you my dude I appreciate that !
Yeah Gary! Here we go! I've got the bbq shapes and am settling in.
Hahaha yea! Bbq shapes are best !!
Can never go wrong with 105SC. The staple of the 90’s
That’s it! Def a classic
Well done! It makes me miss my old cannondale.
Cheers mate! Ya it’s a fun one pretty quick
That came out rad Gary! That color is so nice. Looks like a quick ride too!
Cheers mate ! The color looks great in the sun , and yup nice to ride very fast indeed haha
what a beauty!! grawet work, appreciate these long step by step videos!
Thank you my g I appreciate that ! Cheers 😊
Such a nice result 🤩 and such a detailed explanation 👍
Thank you my dude glad you liked it ! Cheers 😊
Good job Andy you kept the age of the bike in really good taste
i like how you finish your wraps, from now on I'll do it Andy's way
Turbo saddles don't fit my butt lol I would have done a Brooks in Kevlar, but that is just me
keep it coming Andy
Cheers mate glad you liked it !👍👍
Awesome job, I admire your patience.
Thx u my dude I appreciate that 😊🙏
Dude are you a genius? I didn't even think of putting a spring in that BB tool! That should be very useful.
Yes! Very helpful, it’s the Pedro’s bb socket tool
The color is fantastic. I can see why you wanted to keep the paint. It's actually very close to the color of my 2023 Kona Rove.
Hell ya such a nice color , didn’t want to sand it back haha ! That’s cool glad they are still making bikes this color !
Thank you for saving this frame 😊
My pleasure! Thanks for watching 🙏😊
I loved this build, man. Great work
Cheers Bryan ! I appreciate that thx u 😊
Nice Cannondale Gary!! I was looking forward to this one for a while🙂
Thank you my dude ! Glad you like it , gotta love them old cannondales !
Awesome, I just picked up a Cannondale, found your video and, enjoyed it thoroughly
Great job! Now im inspired to try the same
Awesome mate ! Glad you like it ! just be careful with the tubing it’s quite thin but you’ll be right 👍👍 cheers!
Inspirational stuff. And I learnt so much from your video. I'm about to do something similar to my 1996 Giant CFR3. It will be a journey back to my early cycling days. Ditching the RSX brifters, which I've never truly liked, for a pair of Suntour friction downtube shifters and Sunrace R31 aero brake levers. And yes, proper toe clips as well.
Hell ya that’s awesome ! Love the friction shifters for a clean cockpit , I think the old
Sti kinda look like alien heads haha. The new ones now look way better but there’s something about friction that feels good 👍
Thanks for the detailed explanations and quality craftsmanship!
No worries ! Hope it was helpful cheers !
Great work, just the right amount of leave-it-alone.
Thank you I appreciate that ! Sometimes that’s the hardest part!
Nice job. I love how Cannondale used to finish their frame welds. I wish they still did that. Now they look like a Walmart bike.
Cheers mate , ya loved the old cannondales , they were classics!
Nice Gary! i have the same colour R400 1995. love it!
Wow awesome!! Ya it’s a great color I like how it transforms in the sun ! Cheers !
I've loved following you build for the past couple of years. I'd think about investing in an ultrasonic cleaner - you will not believe how nice and clean the parts come out. After watching your videos I bought some evaporust - wow great stuff.
Yesss I def want to try one one day, it’s on the list 😂 cheers mate 🙏
Looks nice - you did a great job restoring it. I have kept my 1994 Cannondale R300 in the garage in between rides and it is still serving me well after 30 years and looks pretty close to new, with no rust that I can find. It has the blue/purple fade paint job that still looks amazing after three decades. Most components on my bike are original except for wheels - one wheel had fatigue cracks at nipples and Mavic gave me a new built rear wheel with a Shimano 105 hub in the early 2000's and I recently replaced the front wheel with a new Mavic/Shimano 105 hub since the original's bearings gave out. I got rid of the Dia-compe brakes soon after purchasing the bike in 1994 because they were so poor and have been very happy with the 105 dual pivot brakes since I put them on the bike. The Exage EX500 derailleurs and crank are in great shape, though I on the third or fourth chain. I think I probably have about 10,000 -12,000 miles on the bike - not much for 30 years.
Awesome that sounds great ! The 105 parts are great upgrades, super solid. Glad to hear that the exage is still lasting too!
@@garysprojects thanks. Now that I am thinking about it maybe the bike has closer to 20,000 miles on it. (I put at least 15 miles a week on it as ride a hybrid on gravel several times a week). In any case, it is a great bike and I don’t think I can bring myself to get rid of it.
@@barryw9473 she’s a keeper !
6:54 very nice moment!!! not stuck!!!
Hahah yessss
Enjoyed that, turned out great. Cheers mate!
Cheers Simon i appreciate that thank you !
Just top work man - you have done 100% justice - come and do up my Cannondale
Hahah Thank you mate I appreciate that !!
Looking forward to this one
We live right now! Cheers !!
The australian master is back!
Hahah just an amateur
@@garysprojects Nah man, you up there with Hambini, PT and many more ;)
@@bnp4292 hahah cheers i am honored :D
Great work Gary! Greetings from Mexico
Cheers mate ! Gday from Melbourne australia
Nice work, man. That bike needed saving and you did it! I see these old cannondales a lot and I might consider picking one up now.
Cheers Cam ! Yes they are nice bikes just make sure to check for cracks ! 😊
That's how they got the name Crackondale😂...I love them !! This one came out pretty nice man !
@@davidwhocares3293 hahah I’ve heard that too , classic ! Cheers man appreciate it
Awesome restore, great vid!
Thx u v much ! 😊
Great video! Super interesting to watch! 🚲
Thank you very much !
Sweet build
Thank you Jeroen!
That is such a pretty build! Love it!
Thank you I appreciate that ! 😊
I like the Asahi touch!
Hahah yessss adds a bit of flair
Awesome man.
Cheers man i appreciate that ! 🙏
Great job. Nice and clean
Cheers mate i appreciate that !
This bike was all rusty and tired, now look at it! Beautiful! Always good to see old bikes back on the street. Pity you couldn't help the old RSX shifters with new hoods - these shifters usually work just fine if you clean them as you did, but the hoods are hard to find and/or expensive.
Thank you my dude I appreciate that. Yeah it’s a shame they still don’t make the hoods! I’m surprised nobody has started 3D printing them yet. There has to be a cheap alternative some where !
Nice bike man, greetings from Germany
Cheers mate I appreciate that!
Great content and tips
Cheers Mike!
That was great job 😊
Thank you David I appreciate that !
The whole bike is very cool but I really loved that seatpost
Cheers man! Ya that seat post is a beauty!
quick tip on getting the UG cassette cog off, since i didn't have a second chain whip either: I used an old chain wrapped around the largest sprocket and clamped the chain down in a vice to hold the wheel in place. Then I used the chain whip on the smallest thread on cog to remove the cluster. Works a treat 👍
Ooo that’s a good tip! I don’t have a vice but I might have a clamp of some sort. Cheers !
@@garysprojects Happy to help - love your restorations! The bike came out incredibly nice and the Exage groupset looks amazing :)
@@donttouchthisatall cheers my dude that means a lot thank you ! 👍
I have this frame and am fixing it up. Ordered new tires - was sent one that was the wrong size (thanks Amazon). 28’s wouldn’t fit on the rear - the front derailleur was in the way. 700x28’s do fit on the front tire.
Good to know ! At the end of the day happy with the 25c as the frame will have a bit of flex when you pedal hard. I however did have someone run it with 28s and had no problem but I think depends on the type of tyre / rim you use as well. All brands are slightly different in width even if stated the same size unfortunately 😂
Great video Gary. Sometime the drive side bottom bracket is harder to remove. Most of the stress is on that side. Love Evaporust.
Ahhh I see that makes sense!! Cheers man i appreciate it !
Beauty ❤ I have R800 2000 still looks like new.
Thank you! Ooo that sounds awesome !
I really love the Asahi detail!😂
Hahahahah my fav too !! 😂
Excellent job and interesting 💯🎯
Thank you be very much I appreciate that
Bike had classic lines forever…the Giant TCR frames started to change that a bit…but heck I’d love a full carbon ONCE team bike
Cannondale and Klein still kept the classic geometry even with the big tubing…it’s the foundation of what makes these bikes so pretty
Hell ya I totally agree, they got the lines just right 👌classics for sure
Have you ever had your hands on, or thrown a leg over the older 3.0 frames with the cantilevered rear dropouts?….i have 3 of them and I would buy one or two more…lightning fast and super stiff
Ahh nah I never had the chance !
Watching you on the bike was sweet…top tip parallel to the ground, right wheel base, and fast direction change…one could cal these bikes almost twitchy….high performance actually
Perfection
Top tube🙄
Tight wheel base….
Holy proof read!!!!🤷🏼♂️
Haha cheers mate ! I think this bike has a classic geometry, haha no worries on the spelling I understood 👍👍👍
Hey Gary,
this looked like way more than 0.7mm.
You are plenty good with 28mm tires in that frame. Cheers
It’s 0.7 mm clearance if I fit 28c on, I only have 25c on right now, however if I ever get a space 28c I will def try it!! Cheers!
in place of a proper hanger alignment tool ive found putting a derailleur then with the allen key still in the derailleur bolt (a long allen works best) i use the allen key to gently bend the hanger while using my hand on the whole derailleur to help out. you may need to tighten/loosen the bolt to find the proper angle that you need to bend. Works well if you go slow checking your adjustments often. Most effective with brazed on steel of course but i've saved many alu hangers
awesome build and video as always gary!
That’s a great tip thank you I will give it a try! Cheers mate ! 🙏😊
@@khalilnaouai4702 cheers mate i appreciate that ! 😊😊😊
Interesting video you made a nice bike from your hard work very good. Tushingham Electric Bikes UK
Thank you mate I appreciate that !
Saw this exact model at the thrift shop yesterday
Hell ya should save it !
Looks fast just standing still
Hell ya thank you !
A little thing to point out because you were talking BioPace - They're really good if you have knee problems. I tore my MCL, and having a set of these on my bike has been a life-saver - I have an easier time pushing a BioPace 48t front and 13t back (108 gear inches) then a round 42t front 12t back (103 gear inches).
The Patent on Biopace Expired a bit ago, I really would love to see like, someone do a 36t Narrow-Wide Biopace for 1x, the design actually lends itself to slower pedaling speeds you'd experience while doing gravel or mountain biking and makes it feel like you're pushing a smaller gear then you are.
Ahhh that’s good to know thanks for sharing ! Didn’t they recent release oval chainrings again into the bike industry ? Can’t remember. Thanks for the info !
@@garysprojects the newer oval chainrings offsets can make them feel about 2t bigger or smaller depending on how they're indexed, but BioPace by not being a true oval feels way smoother to ride, the ramp into the bigger part of the chainring happens at a much more controlled pace. The best way I can describe it working is if you stand to pedal, Biopace smooths out your 'stomp' so you don't give your knee whiplash at the bottom of the stroke.
On that note, if you index oval or biopace to increase power output, it makes it real easy to thrash your knees - Imagine it feeling like you shifted from a 36t in the front at 3 o'clock to a 32t as you hit 5-6. If you know what you're doing, it can aid in power transfer, but if you don't you're going to hurt yourself as it effectively makes the gear easier to push and speeds you up on the recovery part of your pedal rotation.
Whoa, that bike is short! Also making all the road purists angry with bmx platforms hahaha,thats what I do too!😅
Haha yeah it’s 54cm square! Yeah just flat pedals ay, I usually like walking around so rather those! More comfy
Awesome bike, so thoroughly worked. Looks great. But aluminum frame and 25 mm tires, when riding don't you feel every grain of sand on the ground?
Hahah not as bad as I thought actually , I just pretend I’m in the Tour de France 😂😂 cheers mate!
Hi Gary! Super clean bike!
Do you remember if the two holes of the frame, where the screws for the dropout hanger goes, are threaded or not?
many thanks!
Hey mate, sorry I can’t remember but my guess is that they are threaded
@@garysprojects No prob! 👍
You may want to trim the handlebar shim to fit beneath the stem clamp- as they are, they will tend to trap dirt, but worse, pose a hazard to cutting a finger. Otherwise, nice build!
Thank you my dude !
Late to the game, here, but this is why I never used keyed washers anymore for threaded headsets. As long as you properly torque the cup and the locknut together you'll be fine for years and years.
Ya those things are annoying as hell ! Always prone to damage the threads
This is awesome. Quick question, is it okay to use the same housing for both the brake cables and the rear derailleur cable? My bike is also friction shifting if that makes any difference.
Yes definitely okay ! Usually brake housing is slightly bigger than gear , but I’ve been using the same for a long time and no issues
another awesome video gary!!
what's that small red ratchet tool you're using throughout the vid btw? seems neat
Cheers man I appreciate that , it’s a presta cycle tool, available at beautbike.com.au if you’re in aus
I see later in your video you found a pair of gloves. You have a good tool kit
Cheers mate ! I should always remember to wear my gloves !
GJ!🤩
Ty😊
Great job. I liked that you have installed the shift handles on the down tube, but I do not like the pedals. They should have been smaller and grey, just like the levers. Second, the brake handles would have been nicer in silver. Regards.
Thank you mate ! No worries, everyone has different preferences, cheers!
@@garysprojects That's right.
you ever wrap the bars all nice, tape up the end, put in the bar end plug and it doesnt look right, so then you gotta unwrap it all just to fix the bar end side?
Always hahaha
Wow!! it looks incredibly sleek. does anyone know what the name of the bike color? By the way excellent work Gary
Cheers mate ! I’m not sure if the color name myself but would like to know !
beauty
Thank you my dude
sweet
Cheers!
Bartape job are excellent 👌🏻
Thank you !! I appreciate that 🙏😊
Aqui no Brasil eu restaurei uma Monark 10 e Uma Caloi 10 duas bicicletas de estrada fabricadas localmente nos anos 70 e 80, acho muito bom trazer essas biciletas de volta a vida, são uma excelente opção para as bicicletas mais caras e cheias de tecnologia que, francamente, as vezes são pouco aproveitadas....
totally agree , there are a lot of classic bikes back in the day , and its great to make use of them! sometimes more reliable than the newer bikes!
Nice
Cheers
Someone who buys vintage cars wants the cars with all the original parts on it
Haha yes definitely
Hi, did you ever try solder to fill in the holes and then lite buffing . Iam just saying 😊
Wait which holes? I forget
Should do an 80s or down tube group bike ride in Melbourne
haha that would be cool!
There used to be a retro ride about 10-15 years ago. I am in but also need to include MTBs.
I'm working through your video still, but have you heard of a product called Colonel Brassy? It's this sort of abrasive paste I use on chrome and stainless. If you've ever used it, I'd love to know how it compares to T-cut. I don't think I can get that here in the US.
Oh I never used that before! I think I got my t cut off Amazon on something
@@garysprojects I'll look into it, or try to find something similar. I have three different paint polishes and they don't seem to cut as much as T-cut does.
@@ridethroughlifertl nice I heard that turtle cut and wax works well too
@@garysprojects Thanks, I'll look for that. I have Turtle Wax polishing compound, and it's the least abrasive thing I have.
Oh fair enough , good to know !
I trust these frames more than the more recent ones….. they seem to have pure aluminum versus recycled aluminum. Excellent rebuilt……
Oh really!! I didn’t know they used recycle aluminum now. Thank you my dude !
@@garysprojects frames are generally 6061 Aluminium though there are a few 7005 (my Kona for example). All aluminium extrusion/wrought alloys are made from virgin aluminium unless the manufacturer actually sold one the alloy in the first place and they know exactly what it is. The problem with scrap is that the exact composition is generally unknown so it can't be recycled into specific alloys but is used as feed for casting alloys.
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