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1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project - PART 8

The build is complete and the results are like taking a step back in time. It looks like a new bike. It feels incredibly light considering it is a bike from 1998. It actually feels lighter than my modern carbon frame bike. I would have to weigh it to determine if that was actually the case but it is certainly lightweight.

I have been meticulous with the build. I want it to be the best it could be and have used nothing but top quality parts in the best condition I can find. I have not skimped on anything. Everywhere I can use the best components I have certainly tried to do, using period parts. The results speak for themselves. Have a look at the photographs. The only thing I am slightly disappointed with is the bar tape colour. Bianchi have changed the Celeste colour over the years from being more of a green colour to have more of a blue tint, and the corresponding bar tape colour has changed to keep in line with that colour change. I have tried to source some NOS Bianchi Celeste colour cork bar tape to be more in keeping with the colour used on the frame, but I have not been able to source any as yet. The modern colour is not bad but not as accurate in colour as I would like. However this is a minor detail in comparison with all the other parts used on the bike.

I have not ridden the bike as yet as it is not the right time of year to be out on an ultra nice bike, but I will no doubt do so in due course. Having another Bianchi Mega Pro XL in Boron Steel with Campagnolo Record Titanium 9 speed groupset, I expect it to ride equally as good, if not better, than my other bike.

I hope you have enjoyed seeing the progress of the build to this ultimate completion.

1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project

PART 7

Further to the previous cassette lock ring problem on the build of the Bianchi Mega Pro XL Boron Steel Bike, the second problem I encountered was one I was rather expecting. Although in an ideal world I would love to build the bike using Vittoria Open Corsa TT (700x19c) tyres these have been unavailable for many years now. Not only that but top of the range tyres are no longer produced in colours other than black. The yellow tyres suit this bike down to the ground, more so than black tyres. Vittoria do produce a range of colour tyres in the Rubino range, but with the bike being such a high spec, I really want to use a top end tyre and the Rubino tyre is just not quite good enough. The latest Vittoria Corsa Pro tyres would be my choice with the white (gum) wall, but the smallest size they start in is 700x24c. Vittoria Graphine+ come in a 700x23c which is better for this bike, but still there is a clearance issue. There is generally nowadays a move towards using larger tyres on road bikes as it has been proven there is little additional rolling resistance, if any, and they offer a more comfortable ride. However for bikes originally produced to use thinner tyres, this can cause a problem due to the frame geometry.

The clearance issue for me was luckily not to do with the frame or the brake calibers, which is often the case, but with the front derailleur mount. As you can see from the photographs it was just touching the tyre, but being aluminium I modified the mount by filing it to give the relevant clearance, with no noticeable evidence that the mount looked modified. The mount incidentally is a separate part to the front derailleur, the derailleur being a braze-on derailleur. I therefore was more comfortable modifying the mount as a replacement mount is relatively inexpensive if the modification did not work. I have however done this modification before on another bike so was confident it would work.

As you can see there is significantly more clearance now, with little evidence that the mount has been modified. I could possible get away with using the Vittoria Corsa Pro tyres in 700x24c size, but for now will use the 700x23c Vittoria Corsa Graphene+ tyres.

My next update should be the bike completely finished and ready to ride.

1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project

PART 6

So the build of the Bianchi Mega Pro XL Boron Steel Bike is going well, and almost complete. However two problems have presented themselves. One was a problem I was sort of expecting and I have a solution to resolve it. The other was somewhat an anomaly that really took me by surprise. So in the setup of the gears I had a really nice gear change with smooth chain operation in each gear apart from on the smallest sprocket of the rear cassette. Whenever in this gear the chain slipped. It is something I have seen before when a new chain is put on a worn cassette, but I could not quite understand why this was happening with a new chain on a new cassette. It took some working out but I realised the problem was with the cassette lock ring. When you look at it the lock ring is was impeding on the chain being able to sit properly on the smallest sprocket. The lock ring is in fact too large. I had a search through my parts and found another Campagnolo lock ring that had a smaller diameter, but when I came to fit it, the threaded part of the lock ring was too large so would not fit. It all seemed rather unusual.

It turns out that for a very short period of time Campagnolo during the 9 speed Record years of production used 26mm lock rings and free hubs. It was a short period of possibly only a year or so. After which time they changed to 27mm. This explained the difference in the thread sizes of the Campagnolo lock rings I had. I therefore started to search the Internet for a smaller diameter 26mm thread lock ring and found that lockings were specific to whether you were using a cassette with an 11t small sprocket, or a 12t (13t or 14t) small sprocket.

Unfortunately Campagnolo never produced a 9 speed Record cassette with an 11t small sprocket and hence did not produce a 26mm threaded smaller lock ring. Therefore using a 10 speed cassette with an 11t small sprocket on a 9 speed hub with a 26mm thread lock ring is not something Campagnolo have catered for.

My dilemma has been what to do to solve the problem. I considered having the larger 26mm lock ring machined to be smaller, but by chance I found on the Internet a UK engineering company called ‘Royce’, produce and machine some amazingly top quality hubs, and in fact produce a Campagnolo specific smaller diameter 26mm lock ring, specifically to resolve the problem I have encountered. The lock ring in question they produce is made from titanium which will go very well with the titanium parts that I have used to build the bike. Being made of titanium however the cost of the lock ring is not cheap by any means. However, in order to resolve the problem, and to be in keeping with the to quality parts I am building this bike, I bit the bullet and purchased the part.

When it arrived you can see it is a precision manufactured part and weighs next to nothing. It fitted without issue and resolved the chain skipping problem. It was an expense I was not expecting but I am certainly no disappointed by using this part as it really is a very well made part.

1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project

PART 5

I managed to source a NOS Campagnolo Record Titanium 11-21t cassette which again will be ideal for a bike of this caliber. Nowadays most people want a cassette with a wider tooth range as possible, but back in the day it was common to see small cassettes, and it still looks great on the bike. The downside is it makes it much harder to climb, but cadence speeds tended to be slower than they are today. With less science in cycling the cadence speed was generally lower with cyclists pushing much higher gear ratios. It will make this bike more of a flat road bike for the most part.

To complement the chainrings and cassette I have a new Campagnolo Record 10 Speed Chain which is currently still manufactured and available.

I have both Campagnolo Record Titanium 10 Speed Front and Rear Derailleurs, the rear also incorporating carbon into its make-up. Both are extremely precise. The rear is still currently available though with very limited stock. These are no longer manufactured and will soon be unavailable. The front derailleur has been unavailable for some time and I sourced a front derailleur from a guy who had the front derailleur on a bike as part of a display. It has therefore been fitted but never use and so still is in new condition.

The brake calibers are again from the 10 speed range of Campagnolo Record groupset. They came from the same guy who sold me the front derailleur so these callipers have been fitted but never used on a bike that has been ridden. They are again in as new condition and I got them at a very good price over new items which have not been available new now for some time.\

To top off the build I have a pair of Elite Ciussi Stainless Steel Bottle Cages which were as used on Pantani’s bike (he only rode with one cage though). These are still currently available new. They used to be also available in aluminium but now are no longer made. It is therefore only a matter of time before the stainless steel version may cease production, so I feel I have purchased them at the right time.

Other than bar tape which I intend to use Cinelli Bianchi Celeste Cork Bar Tape, and tyres and inner tubes, where I intend to use Vittoria Cross Graphene Tyres and Vittoria Latex Tubes I think that tops off the components to be used in this build.

My next update will more than likely be once the build is complete or near completion.

1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project - PART 4

These are some of the parts I have accrued to build the bike with most of which are New Old Stock, though some parts are used but in nearly new condition. The Campagnolo Record Titanium 27.2mm Seatpost I believe was only available in 1999. After that it became an alloy seat post. You occasionally see the titanium version for sale but they are bonkers money. I was lucky to find a seller in Leeds who has one in very good condition.

I love the Selle Italia Ti316 Yellow Saddle. I use this saddle on a couple of my bikes and have long since been on the look out for one in NOS or near new condition. This one I sourced from California as I have been unable to find one in good enough condition any where in the UK for the last few years. They are very stylish and are comfortable, and with titanium rails are lightweight.

I managed to source a NOS boxed Campagnolo Record Threadless Headset. These are not very common any more. You can still get the threaded version of this headset, but to find a treadless one in unused condition is very difficult. It was reasonably priced, but they are becoming rather expensive.

This ITM Big One Stem has come boxed and I have had it for a few years. There hardly ever come up for sale a new items, more likely used and not in the best of condition. A black one is much easier to come by but this mustard yellow one is the one Marco Pantani had on his bike and so suits the bike. It really does complement the bike well.

These ITM Super Italia Pro-2 bars are again a NOS item which I sourced from Italy. They are top end alloy bars and being ITM are in keeping with the make of bars that would have been used back in 1999/2000. ITM did produce a titanium set of bars, and I actually do have a set of these on one of my bikes, but I have never been able to source another, and can barely find any information about ITM titanium drop handlebars. These alloy bars are considered to be a pro level component. They are Italian, in keeping with the bike, and are very stiff due to their Ergal 7075 Alloy construction.

The Campagnolo Record Ultra 10 Speed Carbon Shifters were the shifters to have in 2000. They are the top end shifters for the Record Titanium groupset, being very precise lightweight. The pair I have here I have owned for a couple of years. They are nearly new items with very little use. They are in exceptionally good condition, and I got them at a relatively bargain price in comparison with the new price both back in 2000 and what they would be now.

The Campagnolo Record Titanium Carbon bottom bracket is again something I spent a lot of time sourcing to ensure I got the carbon version which would have been correct for this groupset in 2000. This one came boxed and clearly has not been used.

The Campagnolo Record Titanium 170mm 53/39t Crankset is in exceptionally good condition. The crankset for the most part has not been fitted and used and comes with the chainrings which are correct for the 4 armed record crankset. Replacement chainrings themselves are difficult find in their own right so I was very lucky to be able to find NOS crankset complete with unused chainrings. This crankset will look fantastic on the bike.

1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project

PART 3

Wheel building is something that I do as part of my bicycle repair business and although is not something I do everyday, it is something I am passionate about doing right. I do not rush the process as you can’t in order to get a really nicely built, trued, dished and tensioned pair of wheels. I am meticulous about getting them running absolutely true, and the hubs and valve hole lined up. With this bike I was considering what would be the ultimate wheel build that would be in keeping with the frame. Looking at Marco Pantani and the rims he used to ride, he was often on Campagnolo Electron wheels which were a narrow section rim. They were however tubular rims, and I particular want clinchers as I know with a clincher that I can easily repair a puncture and be on my way within 15 minutes whereas with tubulars a puncture can leave you stranded. I was therefore looking for ideally Mavic MA2 rims which are silver in colour which would also be in keeping with the period look of the bike. Ideally I wanted 32 hole rims, as I had was looking for 32 hole Campagnolo Record Titanium hubs. These hubs are less common than the 36 hole version but I think a 32 spoke wheel will look better on this bike than a 36 spoke wheel. The 32 hole hubs took months to find. There were a pair of boxed NOS on eBay for ridiculous money, but I managed to find a pair for sale in the USA, with very little use in exceptionally good condition. The rims I really struggled to find. The rims I most definitely did not want used rims as you never know if they have been buckled and it can be very difficult to build them to run true with an even tension in all the spokes. I ultimately ended up finding H Plus Son TB14 road rims which are built in a similar way to the Mavic MA2 rim and have that classic bike rim look that I believe will suit the bike. With the Boron Steel frame having a narrower gauge tubing that the Aluminium Mega Pro frame I believe it will suit a narrow rim well.

The hubs when they arrived are beautifully made and feel so smooth both in the spindle and the freehub. They are virtually unmarked and once built as a wheel with a cassette it will be difficult to tell they are a used part. The rims arrived very well packed and look amazing in polished alloy silver.

The wheel build went extremely well. Both wheels tensioned very evenly to create a pair of wheels that are extremely true. They spin for ages with no balance issues. I chose to build both using DT Swiss Competition Double Butted Stainless steel spokes and brass ni***es. For less weight I could have used aluminium ni***es but I do not like them as they have a tendency to corrode and react with contact with the steel spokes. Brass does not have that issue. I cannot wait to see these wheels on the bike. I think they will suit it so well.

1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project

PART 2

Following on from the purchase of the Bianchi Mega Pro XL Boron Steel bike, it went into storage for a few months to give me the opportunity to bide my time to purchase the relevant parts I was specifically looking for to have everything in place to build the bike as I wanted it. I was looking for New Old Stock parts where possible, and failing that parts that had seen little use. I was obviously price conscious also, but was not willing to compromise on quality for the sake of price. For me this is to be the Ultimate bike build so nothing less than Campagnolo Record Titanium parts for any part of the groupset would do. Even the hubs, although you can get Campagnolo Record hubs, I specifically wanted the ‘Titanium’ version which comes with Titanium spindles. They are the very best components that were and are available for that era of bike. With the bike frame completely stripped down, I set about cleaning the frame before then polishing using Autoglym car polish. I find it is one of the best ways of restoring the paintwork on any bike frame to identify any imperfections such as deep scratches or paint chips that may be in the paintwork. I believed the frame to be in good condition, but sometimes it is easy to miss marks in the frame not necessarily easily noticeable when the frame is a little bit grubby. I was pleasantly surprised however by how good the frame and paintwork was. The previous owner had done well to protect the frame from cable rub and chain slap, and with a good polish the paintwork was back to a super gloss finish. Only very minor touching up was needed for the frame to be once again in mint condition for its age.

One issue that can arise with these Bianchi frames is that the clear coat lacquer can yellow a little over time and cause a change in the Bianchi Celeste colour. It is easily noticeable as it does not yellow evenly over the frame so you see changes in the colour particularly around the bottom bracket area. For the most part this has not happened to this frame, so the Celeste colour is very much as it should be.

With the frame now polished up it is time for the rebuild.

1998 Bianchi Mega Pro XL Boron Steel Bike Restoration Project

PART 1

A little while ago a friend of mine mentioned he had seen a bike similar to mine in a local bike shop window. It was second-hand but looked in reasonable condition. I was not looking for another bike at the time, but was curious as to what it was, thinking it would be the more common Bianchi Mega Pro L Aluminium framed bike, often specced with Campagnolo Veloce groupset and often not overly well looked after. By sheer coincidence that weekend we happened to cycle past the said bike shop, and I fancied having a look to see what the bike was. To my surprise it was a rare version of the Mega Pro, the XL in Boron Steel and looked through the window to be in pretty good condition. Being a bit of an enthusiast of these particular bikes I went in for a closer look.

For the most part I was not bothered about looking at the components or spec of the bike, more the condition of the bike frame, which I quickly realised was in exceptionally good condition for its age, despite being a little bit grubby in places. Chatting with the bike shop owner it would appear this bike was purchased new to the spec seen here, and was part of a larger collection of bikes the owner was selling off. It had been regularly maintained, had not seen a lot of use, and all the components were well maintained.

Now this bike frame could quite easily be built as a Pantani bike replica, though to be technically accurate it would be an aluminium version of the Bianchi Mega Pro XL (a frame I also own as a built bike). The aluminium version of this frame has slightly wider tubing, and slightly different lugs and cable mounts, but the colour is identical, and to anyone not in the know they would not know the difference.

Not really having the room for another bike, or indeed particularly looking for another bike, I was simply interested in seeing it with no real intention of buying it, yet over the next couple of days I found myself thinking about it a lot. I subsequently decided that due to the excellent condition of the frame and was at a bargain price, it was worth buying so as to save it from being abused by someone who possibly did not realise just what a superb bike frame it actually is. In saving the bike my intention was to completely strip the bike down, clean and polish the frame, and rebuild the bike using Campagnolo Record Titanium 10 Speed Groupset which for the most part I already owned. I simply fancied building this frame to be a top of the range bike using the very best components you could have bought at the time around that 1999/2000 era.

Now I know some of you will be thinking it should be 9 speed for that year of bike, and yes to be authentically correct it should. However I already owned Campagnolo Record Titanium 10 speed shifters, a 10 speed rear derailleur, a 10 speed cassette, and a 10 speed crankset, and back in the day it would have been a natural thing to do to potentially upgrade your 9 speed to 10 speed when the new groupset came out. I therefore think a 10 speed would not be out of place on this frame. I was however missing a few parts including seat post, saddle, headset, bottom bracket, and hubs / wheels. In addition I was also missing a saddle and a better set of handlebars, but with a few parts to get I set about tracking down some very rare parts.

This is the first part of the story of what I believe for me is the ultimate bike build.

This is the time of year to have your bike serviced ready for some dry spring weather. More and more cyclists are using their summer bikes during the winter, and riding without mudguards, or getting their summer bikes out too early in the year whilst salt is still being spread on the roads. The result can be quite significant causing corrosion and premature wear if the bike is not cleaned and lubed after each ride.

Here is a specific example of a bike used during the winter, where salt and water has reacted with the aluminium and steel parts of the bike. Brake callipers that are stiff and do not retract fully, more pressure required when using shifters due to stiff cables, derailleurs that struggle to change gear, bearings that are rusty and worn, and chains with links that are seized are all common problems. If left too long parts need to be replaced resulting in an expensive bicycle service, where a little bit of cleaning and maintenance after each ride could have saved a lot of expense.

Book your bike in for a service now in preparation for that first beautiful day of spring, so you can enjoy a lovely ride on a fully working, safe to use bike that rides like new.

A very interesting article about hookless wheel rims.

https://www.globalcyclingnetwork.com/tech/news/hookless-rims-under-cpa-scrutiny-after-thomas-de-gendt-crash-at-uae-tour?fbclid=IwAR34gDiSx8fCAWdBFfHm_W_2Sb3abZBrrbiRtQn_BmFFuApeAO4losmWOFs

Hookless rims under CPA scrutiny after Thomas De Gendt crash at UAE Tour Riders' association president Adam Hansen blames hookless rims for crash while Lotto Dstny defend the set-up

Bicycle Servicing and Preventative Maintenance - Keeping your bike clean will help prevent unnecessary wear.

Simply cleaning the bike on a regular basis will help prevent wear, prolong the life of parts and ensure that everything works well. Regularly servicing your bike will keep it running like new to make it feel like new.

Located North of York between Boroughbridge and Easingwold we are a Cytech trained experienced bike workshop, open for bike servicing and repairs. Contact us on 07944 742241 or by email to [email protected]