Salvaging a Hub

I know I have lots of updates to give on various projects, which I will hopefully get to this week, but in the meantime, here are some photos of my latest project, which is really just a side project for the Phillips roadster.

My friend Mauricio tipped me off to a cheap junker bike at a local estate sale. I picked up what's left of this 1964 Huffy Sportsman for $10, and I'll probably be able to salvage a few things, but the main thing was the rear hub. It's a Sturmey-Archer TCW III, a three-speed coaster brake hub. Sheldon Brown says the TCW series is unreliable as a coaster hub, citing possible failure of the brake if the cable is not properly adjusted, but for the money, I'm willing to give it a try.

My wife has hinted that perhaps she would like to ride the Phillips when it's finished and she really liked the idea of a coaster brake. I, however, wanted to put a three-speed hub on it, so here's the compromise, which suits all parties. True, it's not period-correct for the Phillips, but the correct K Series Sturmey-Archer hubs seem to be hard to come by and somewhat expensive, and not available in a coaster brake model. We'll have the rod brakes, too, just in case there's a problem with the coaster brake.

Here's a little photo series on my efforts to salvage the hub:

The before photos:

I had to cut the spokes with a pair of aviation snips because the nipples were too corroded to turn and the spokes too rotten to reuse.

Below, the top layer of gunk and rust has been scraped off:

Below, rust removal continues with fine steel wool, penetrating oil, rubbing compound, and even very carefully applied sandpaper over the worst rust spots, never used directly on the chrome.

The external cleanup on this hub is probably about half-finished. I'm hoping for near-pristine by the time I'm done, but it's going to take a lot more elbow grease to get there. I took a peek at the internals, and everything is surprisingly clean in there, so maybe I can get away with not dismantling it entirely.

Posted in: brakes,hubs,Sturmey-Archer