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Technical & Reference Section => Tech and Restoration => Topic started by: renegaderacer on February 25, 2012, 04:58 PM

Title: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: renegaderacer on February 25, 2012, 04:58 PM: Whilst I was building my Badlander I built up an impressive collection of spares and decided to build them into something cheap and fun to ride.

All I needed was a frame and forks! It was then I saw rakas17 was selling some Falcon Pro Aero Flyer ones on eBay and thought 'ooh, they're nice; I'll have those!'.

I outbid the hordes of potential buyers and waited for them to arrive. When they did I was pleased about the state they were in thinking they may be more rusty than they were and they are actually a really nice shape and weight. The rust needed sorting but this was exactly what I was after; something which needed work but would turn out sweet in the end!

I read up on this site about the old trick of using Coke and tin foil to clean the rust off the frame and thought it couldn't hurt so I'd give it a go.

Here are some pics of the frame as I got it...

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0516.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0517.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0518.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0520.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0524.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0525.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0526.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0527.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0528.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0529.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0530.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0531.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0533.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0535.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0536.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0537.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0543.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0546.jpg)
There are loads more pics of rust but you get the idea! :LolLolLolLol:

I started by removing the forks and headset and BB cups and removing the decals (very badly) with heat and a Lil' Chizler tool.

I then coated the frame and forks in Autosol and left them overnight; cleaned them and let them soak in WD40.

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0572.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0573.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0574.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0575.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0576.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0577.jpg)

I got my tin foil and Coke and was ready to give it a try!

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0578.jpg)

I screwed up a ball of tin foil, dipped it in the Coke and used it as if I was scrubbing something clean and bugger me, it works!

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0579.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0580.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0581.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0582.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0583.jpg)

I then gave it a good polish with Autosol....

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0585.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0584.jpg)

After the frame I gave the forks a go. I thought they'd be easier but the rust seemed to be deeper on these.

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0587.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0588.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0589.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0590.jpg)

After I'd Autosol'd the forks too I polished everything with Peek and then pop-riveted on the badge which I'd cleaned up but left survivor style (means I couldn't do a good enough job at restoring it! :LolLolLolLol:)

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0599.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0598.jpg)

I sent Del the remainders of the decals and somehow he saw how they were meant to look and did his usual amazing job of producing spot-on replica's of the originals. He even reproduced the original dealer sticker for me! The man's a legend, what more can I say? :daumenhoch:

(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0621.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0622.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0623.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0624.jpg)
(http://www.radbmx.co.uk/archive/albums/ab312/kungfuracer/Falcon%20Pro%20Aero%20Flyer/Photo0625.jpg)

I'm really pleased how it's turned out with very little money and a bit of hard work. Makes it all worth while! Hope you like it too?

Cheers,

Giles ;D
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: rooski on February 25, 2012, 05:11 PM: Come up a treat,good work :daumenhoch:
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: HUTCHMAN on February 25, 2012, 05:44 PM: stunning result!!
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: Discostu on February 25, 2012, 05:58 PM: Great restoration work! :4_17_5:
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: brettypeeps on February 25, 2012, 06:13 PM: Great result :daumenhoch:
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: deeman on February 25, 2012, 09:11 PM: Top work,that looks the nuts now!!I bought my first pair of skateboard trucks from Bob Addys in Watford when i was 12! :daumenhoch:
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: Gnarlyscoots on February 25, 2012, 09:25 PM: Another full marks there dude :4_17_5:

It's good to see some effort going into the 'cheaper' brand of BMX as most people started off on these type of rides and they get stampeded past for high end brands :buck2:

Top draw :daumenhoch:
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: NORTY40 on February 25, 2012, 09:52 PM: Nice resto work mate :daumenhoch:

Frame has come up a great 8)
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: Macmania on February 25, 2012, 10:17 PM: Lovely work and great results :4_17_5:

Now't like sore sticky fingers after all that rubbing :D
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: QUADROPHENIA on February 26, 2012, 09:27 AM: That's pukka you an sweet job on that, that laid in my garden for years
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: oddkiddcreations on March 14, 2012, 03:53 PM: Awesome would never of given it the time of day with tin foil.. :4_17_5:
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: BENDYCAT ELEVENTEEN on March 14, 2012, 04:30 PM: great job and looks loverly :daumenhoch:

just to say - coke and tin foil can be too harsh - along with autosol which can also be a little to harsh - both leave hair line scratches and dull the chrome a bit
peek is better and will leave a better result ;)
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: renegaderacer on March 14, 2012, 04:52 PM: Yeh, that Peek's lovely stuff. I use it on all my stuff now. :daumenhoch:

I agree with you that I wouldn't use it on any nice chrome but I think the state the frame and forks were in though, it needed something abrasive to clean it up before I polished it with Peek! :LolLolLolLol:
Title: Re: Falcon Pro Frame and Forks Restoration (PIC HEAVY!)
Post by: kidretro on March 15, 2012, 11:10 AM: Are you sure it's the same bike ? well impressed. F##k me what does coke do t ya insides , my guts must be super shiney. :-[