Preparing a Tandem Bicycle for the Andes and the Amazon 4

Our rear derailleur after four months and 3,000 miles in SE Asia

When we travel on our tandem in difficult places, like Tibet, and SE Asia, keeping the bike clean is the last thing I’m thinking about at the end of a hard day: food, a place to get horizontal and sleep are first priority, maybe changing money, buying food for the next day, trying to understand your host, the market vendors; all this before sunset since it’s often cold then, or sometimes not the best time for a gringo to be wandering the streets. So this is often when the derailleuer looks like after 3 or 4 thousand miles.

The Right Bicycle Oil is the Oil You Can Get

Of course I would never begin a new tour, South America, the Andes and Amazon, without cleaning this mess. It’s not easy. I will also replace both jockey wheels (that little round thing with rounded teeth) and lightly oil the parts. Often the oil we can find in Third World/Developing countries is not great for bicycles; in the case of this derailleuer, too heavy. But the wrong oil IS better than no oil. One good source of chain oil is from roadside sewing vendors; they’ll usually sell you a small quantity of machine oil for a pittance, and it works well. When you can’t find that, motor oil, or heavy gear oil is all you can get, and it makes the mess you see above, but it also keeps the gears turning.

Between adventures, Zippy and I keep our distance

Once we return from these trips, Zippy and I have a mutual aversion to each other. He just wants to rest, and I want to do no more work on a bicycle, any bicycle other than Zippy. Sometimes this lasts for two years. He sits in the shed, happily resting and remembering his adventures and I give my road bike the attention its missed, and rest. But then, something between Claire and me begins to itch, and we begin talking, sometimes in convoluted circles, about a possible bike adventure in some interesting place. Of course we’ll take Zippy. We did take our mountain bikes to Iceland, but 40,000 miles of our world travels has been on Zippy.

But Zippy, like his senior owner and captain, is showing his age

We both have scratches and dents, some of our screws are loose, most of mine in my head, and it’s getting harder and harder to find replacement parts for what wears out. It’s harder for Zippy than me. I can still heal cuts, mostly, and regrow most of the muscle loss I had in the early stages of starvation in the high altitude of  Tibet. But I know the machine (mine) is slowly aging, just like Zippy, and will have to find more tame pursuits: nice flat rail trails are looking better to me than they did a few years ago. But not yet. For a decade I’ve been saying I have one more BIG trip in me, and then there’s ……… where we haven’t visited yet. And so it goes.

Neither Zippy, our tandem, not I am ready yet to fade into the sweet dotage of old age, just yet.

Claire and Zippy and I, leave for Lima, Peru in a few weeks. There I will unpack, and rebuild Zippy once more, and we’ll pedal for the Cordillera Blanca, the high Andes. This time I hope to stoke up on some fat before we leave and avoid the emaciated look I acquired in Tibet in the early stages of starvation.  We should find more high cold passes, it’s winter in the Southern Hemisphere, before dropping precipitously to the end of the road in the Amazon Basin, where will see how Zippy mixes with river travel, before leaving the Amazon toward the Caribbean coast.

There will be some more posts before we leave, like how to pack a tandem to get the stingy airlines to accept it, and our own personal and financial preparations.

Watch  this space.

Preparing a Tandem for the Andes and the Amazon 3

Good thing the Agriculture Dept. doesn't take apart bottom brackets when we return from these adventures

Bottom Bracket Dirt

You find the darndest things when you remove a bottom bracket from the frame sometimes. This is what we brought home from Tibet and Southeast Asia. No matter how much grease you use, eventually dirt and grit find their way into your frame. We’ve brought home teaspoons of soil from Australia, Asia twice, and I’m sure we’ll bring some back from South America. If we could just stick to nice paved roads we wouldn’t have this problem, and not so much fun either.

I have corrosive sweat!

Do You Have Corrosive Sweat?

Above is another good reason to take your bike completely apart between tours. After our Silk Road trip, I noticed some corrosion when I replaced the handlebar tape. It didn’t look too bad, so I just replaced the tape before going on our Shangri-La tour of Tibet and SE Asia. I guess the heat and humidity of SE Asia, combined with my corrosive sweat, really did a number on the bars. This time I was able to flake large pieces of soft aluminum from the bar, and even poked a hole all the way through with a knife. The bar would probably have broken somewhere in the Amazon Basin, if not sooner. New bars, and replacements for worn out brake levers on the way.

1.25" headset on Cannondale tandem

Can You Rebuild A Headset?

Even though the headset felt great, I dropped (pounded) the fork out and disassembled the headset. Guess what? The bottom set of bearing cages dropped several bearings on the ground. The races looked good, and the bearings smooth, but obviously the bearings were worn a bit. Phil at Pima Street gave me a few bearings. After cleaning the cages and races I pressed new bearings into the cages and crimped the cages a bit. Now they all stay in place, and I’m good to go for a few thousand more miles, after liberal application of some quality grease I got from Steve Wilson Jr.

I could let someone I know and trust do all this, probably quicker, possibly better, but I think it’s important for me to re-familiarize myself with every part of Zippy. Who knows, I might have to go through a street mechanic’s inventory of loose bearings somewhere in Tibet or the Amazon, and put the thing back together sitting cross legged in the dust. I want to be able to look like I know what I’m doing! It’s a man thing.

We have our tickets! No turning back now.

Preparing a Tandem Bicycle for the Andes and Amazon – 2

Tandem cassette after 3,000 miles in Asia

How To Rebuild a Rear Hub For Gonzo Touring

This is what our tandem’s 8 speed cassette looked like after 3,000 miles in Asia; Tibet, Laos, Vietnam, Cambodia and Thailand. Now 3,000 miles is not a lot of miles, unless you consider that the miles went to 16,000 feet in elevation, multiple 7,000 ft days, potholed, dirt, mud roads and jungle paths. So, considering, this cassette doesn’t look too bad. But we’re going to South America, Peru, Brazil and maybe more countries, over more dirt and mud roads, and I need to tear apart the rear hub, heart of any bicycle, and see how it’s doing.

Hugi hub after pulling the cassette body off the hub using the cassette cogs

Inspecting and Refurbishing a Hugi Hub for a Tandem Bicycle

To get into my hub I simply put four fingers of each hand behind the cassette cogs, brace my feet at 9 o’clock and 3 o’clock, and pull. And pull. And pull. Eventually the cassettes, still on the cassette body, comes off, sometimes liberating precious, essential inner parts, flying all over the place; best have a clean surface, and a helper to watch for small pieces of metal departing for greener pastures, tired of lugging you two and your luggage up mountains!

In this case, the mud from Laos, Vietnam and Cambodia, had mixed with the light grease I’d put in before our In Search of Shangri-La journey, kept all the little bits glued in place. Why it was not freewheeling in all this goop, I can’t imagine. However, with this type of no-tool repairable hub (the only kind to have unless you cycle ten mile circles around a good bike shop) I could have easily done this job on the road. Actually, in the 12,000 miles around Australia, I refurbished this same hub twice.

Next, take the paws (?) and springs out, remembering how they go back, and clean them with a rag first, then dish soap and water. Don’t use full strength solvent or citrus cleaners, they can over time, degrade the surface of parts that need to remain smooth to work well. While you have it apart, check the bearings for roughness and hope they feel smooth. It’s not easy to change sealed bearings on the road, but it can be done, so you might carry spares if you are really really out there. I carry spare springs for this hub, the springs being the only thing that has ever failed in this system. After cleaning and drying all the parts, grease them with a very light grease, using less than you think you should. Grease build up, mixed with road grit, is the second reason for hub failure.

Inner parts of a Hugi hub on the cassette side

Inner View of Parts on the Cassette Side of a Hugi Hub

As you can see this hub had some major abuse on our last adventure, in particular pushing for twenty kilometers while lost for two days on an old branch of the Hoh Chi Minh trail in Laos. At least it didn’t run over a bombie and blow us all up; these part would have been really scattered then. After cleaning, I forgot to take a photo, the parts were clean and smooth again, ready for another go at some more mountains, this time the Andes, and probably a bunch of bad dirt roads. That’s why I paid big bucks ($150 or so a long time ago) for a great hub (not a sponsor, we have no sponsors) The hub body has over 18,000 miles on it, and we are on the second set of paws and springs. Not a bad deal.

Outer View of Parts on the Hub Body side of a Hugi Hub

Hub Body View of a Hugi Hub disassembled

Muddy but unbowed! This is the view of the hub body showing the inner parts. While you have the hub disassembled, check the hub body where the spokes go through for cracks, and check the spokes for signs of failure. If you see any iffy spokes, change them before reassembling the hub. Don’t forget to take a few spokes for each wheel on difficult tours. I tape the rear spokes to the rear seat tube, and the front wheel spokes to the fork.

After all parts are cleaned thoroughly, reassemble the freehub body and cogs and the hub body. Since we often put the hubs under muddy water, I usually coat a little grease around the hub before fitting the two parts together. Do the reassembly carefully, wiggling the cogs back and forth until the units sit together comfortably. Test the hub’s ratcheting action. It should feel a little tight, but not much, and catch firmly every time. This is also the time to put on a shiny new set of cogs.

Now your rear wheel is ready for a few thousand miles of exciting tandem touring. And ours is too.

Preparing a Tandem Bicycle for the Andes and Amazon 1

What Tibet can do to a cassette body

Rebuilding a tandem bicycle for a South American tour

I am beginning to dismantle Zippy, our 40,000 mile world touring tandem, in preparation for our next self supported tour, this time South America. Before each tour, I completely dismantle Zippy for three reasons: to find our which parts need replacing so I can order them and fix the worn parts, catch any impending failures of frame, rims or drive-train, and to re-familiarize myself with every part. Since many of the places we tour are hundreds,sometimes over a thousand, miles from a proper bike shop, I have to be able to fix pretty much anything.  Anyone who owns a tandem will tell you tandems need more attention than single bikes; I might have to rebuild the hub somewhere in the high Andes, or the middle of the Amazon basin, while being munched on by ants and mosquitoes and critters we’ve never seen before.

Next lesson; rebuilding the innards of a cassette hub

I will probably not replace this cassette body; it has quite a few thousand miles on it in Asia, and if the hub fails, it won’t be here, but in the internal workings. The next post will show these parts, and tell how you can rebuild your own, on the road.

Mark July on your calendar for the beginning of our tour. It will include the Andes, and the Amazon basin, but water and whatever dirt roads we find appealing. You can click on the RSS feed to get a notification of posts.