Thruster Fixed Gear Bike (Walmart) Rebuilt and Upgraded for 200.00 Total Investment?

Hello and Welcome,
I am not a huge fan of Walmart. Or at least I like to think I am not. But after hearing from a friend that they had seen exercise bikes on display there. I thought to myself, what can it hurt to look? Well after not being able to find an exercise bike that I wanted, I decided to wander over to the bicycles... Just to get a look at the latest in Department Store bicycle offerings. I had no intentions of making a purchase. Then I spotted the last thing I ever expected to see, a single speed bike with a flip-flop hub. However the brakes looked really cheap as did the crank, seat-post, pedals, handlebars and grips. But the frame looked like it could get the job done. And the wheel-set looked entry-level. But they did spin fairly straight, well the rear one did anyway. I`m thinking, this could possibly work with a few improvements. Then I saw the price tag $99.00!!

Above: Oh God forgive me! I have succumb to temptation! ok seriously, I was doing the math in my head. How much did it cost me to build the Schwinn lugged frame fixed gear bike? How much will it cost me to make this thing reliable? Then I came up with the perfect excuse. It was as if the Devil himself were whispering in my ear. "You can make this a really cool bike for under 200.00 Then you can blog about it!" Well There you have it, that is how I came to purchase this department store fixed gear bike. I am reminded of a line from the movie Tombstone when Doc Holiday said "That's what I love about Wyatt. He can talk himself into anything."

Above: A shot of the rear hub and sturdy looking 1/8 bicycle chain. The rear rim is yellow with a red tire and the front red with a yellow tire. I would have preferred they both be the same. I decided to switch the tires so they match the rims. My hope was it would give it a taller look, and to a degree I think it did just that.

Above: A shot of the "cheesy looking" front side pull caliper brake. ˈCHēzē Adjective: cheap, unpleasant, or blatantly inauthentic. Yeah! that is the word I was looking for alright. I have some vintage alloy (side-pull) caliper and center-pull brakes in the shop. I think I can polish-up something that will get the job done and look good doing it. I will not be installing a rear brake. And the resin pedals are going to be replaced with Avenir ultralight pedals with old style clips and straps. I can just see me trying to perfect my skid with my feet sliding off the plastic pedals. Did you ever notice how many other names they have for plastic?

Above: The seat-post and clamp will be replaced. In fact I just received the "your order has been shipped" e mail this morning. I think I have spent about 75.00 or 80.00 so far. The only purchase left is the cork handlebar tape. Which I now need since I have decided to make a set of flop and chop bars for the fixie. So I should be right on target when finished.

Above: I stripped the bike down to the frame and upon closer inspection the crank and threaded headset were both set too tight. But what really bothered me was some of the bicycle grease. It looked like it had been scraped-up off a dirty floor. And there were little pieces of dirt or scrap from the manufacturing process. It appeared that nothing was cleaned-out before greasing.

Above: This photograph of grease wiped off the bottom bracket bearings was an after thought. This pic by no means shows the worst of it. The little bits of grit on this paper towel are barely visible in the photograph so I have marked them for you. Basically I needed to clean all the bearings, races and cups then I re-greased everything. And of course reset the bottom bracket to the proper tightness (or lack there of). The headset was the same story just clean everything off and re grease and reassemble to the proper setting (no play/no grind)

You have seen me do enough bottom brackets and headsets on here for a while. So let`s start with the front wheel axle (ABOVE) with the free bearings. The first thing I need to do is break this over tightened axle loose.

Above: Here I am loosening the front axle using two adjustable wrenches. Once the cone nut breaks loose only one side is going to be removed easily. But that is no problem. We only need one side to be loose to grease both sides. I will hold the bottom nut (tight side)so the axle does not spin as I and loosen the top side (by hand) to expose the bearings for greasing.

Above: At this point you want to keep the exposed bearings facing upwards. You do not want these all over the floor. You also want to keep the opposite side on a table or bench-top. You also do not want the axle sliding out of there. I greased these bearings in place, buy just putting a little grease on my finger tip and packing it into the bearings. I would only do it this way with a new bike.

Above: Here after greasing the bearings I am replacing the cone/nut by hand,leaving the lock-nut off for now.
Once I screw the cone into place (snug not tight) I just wipe-off the excess grease with a paper towel.

Above: Now I have flipped the wheel over and loosened (unscrewed) the top side which is now backed-off enough for me to wipe-clean and re-grease the bearings. I am careful not to back it off so far that the opposite side cone comes off the threaded axle. With a finger on the end of the axle, I can feel when I have backed the top side out to the max. I just stop when the bottom end is flush with the axle cone-nut.

Above: Once I have wiped and re-greased the bearings I can now screw it back down into place. As always not too tight (no play no grind) Afterwards I can flip the wheel over again and replace the (thin) lock nut on the opposite side. When replacing the lock-nut I can use a cone wrench to hold the adjustment on the cone while tightening the lock nut. I suspect this is where the factory screws up and the axles end up being set way too tight. Give it a spin when finished holding the axle at each end. If it feels too tight or too loose try again. Remember "No Grind and No Play" is what your looking for. Now I am ready to move on to the rear wheel bearings.

Above: Removing the fixed gear cog`s lock-ring using a Hozan Bicycle Bottom Bracket Tool. The lock-ring is reverse threaded. So turn it clock wise to loosen it.

Above: The fixed cog is normal threaded (righty tighty - lefty loosey.) So using an Avenir Chain-Whip crank it counter-clockwise to remove it.

Above: This is not how you would want to remove a freewheel unit normally. (single or multiple cog) But there are no slots for a single cog freewheel removal tool. So I will take it apart and remove it in pieces. If I do use a freewheel unit on the bike it will be a freewheel with slots for a removal tool. I`ll save these parts but I doubt I will ever use them.

Above: The remnants of the single freewheel unit. I`m not sure why it was made this way (no slots for a removal tool) Maybe they figured it being a 99 dollar bike, it would not last long enough to ever need a new single freewheel cog. Maybe someone can enlighten me about this design. I did not bother installing a freewheel unit on the other fixed gear bike I built. I do not plan on climbing any big hills on it anyway. It only bothers me because I think it is a stupid design. So lets move onto the rear axle bearings.

Above: I loosened the cone/nuts in the same way I did the fronts. Here I have added some fresh grease and I am ready to screw the cone back into position.

Above: I am now screwing the threaded cone back into position. Like on the front I will set aside the lock-nut for now. I am now ready to flip the wheel over and grease the bearings on the free-wheel side.

Above: Again just like the front axle I will back this side out while holding the bottom side of the axle. And I will be careful not to back it out too far. In this pic you can see I have already greased the bearings and am ready to close it back up.

Above: This pic really shows how the tight side is undisturbed. When I screw this back in I am actually turning the axle. And this side is being drawn back in by the other side being tightened back up. This is why I have set the lock nut (the thin nut)aside for now on the other end. Once it is all closed up again and not to tight or loose I will then thread the lock nut back into place. And I can hold the cone in the proper position by using a cone wrench to hold the cone from tightening while I tighten the lock nut. Again like the front you will need to check this for grind or play before installing the wheel on the bike.

Above: Here is the rear wheel back on the bike for testing, the fixed gear cog is working fine. I have temporally re-installed the original crank for testing. The new crank and post should arrive in a few days. I had already ordered grips before I decided to change the handlebars. I will be wrapping the new bars. But I`m sure I will use the grips on a future project.

Above: Here I have the wheels back on with the temporary crank. Lets move on to the handlebars.

Above: I have marked the spot where I want to make my cut and locked it into the vise for cutting. I am not cutting into the vise :) I had to let go of my hacksaw for a sec to take this pic.

Above: To get the bars cut evenly I use the first cut piece as a templet to mark the other side.

Above: These flop and chop handlebars are going to save me at least $20.00 That is about the least I could expect to pay for bullhorn pursuit style handlebars. And once they are all taped-up I think they will look pretty good too. I think I will mount this front brake lever differently so I can compare the two.(this one to the Schwinn fixie)

Above: I think this looks fine, but I think it will look better if I shorten-up the reach on the adjustable lever. I just need to remember to do this before I trim the cable.

Above: A hack saw can leave razor sharp edges and burs on the freshly cut surfaces. It is best to metal file these off right away. Not only can these sharp edges cut you, they can also cut into your handlebar tape.
My parts order has not arrived yet, So I`m going to close for now. I will get back to work on the Fixie as soon as the parts are delivered. Look for the "Thrasher Fixie Finished" post within a week. Until Next Time, Please Ride Safe and Remember to Always RESCUE, RESTORE & RECYCLE Cheers, Hugh

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Cheers, Hugh