Monday, June 15, 2015

Dave's 1977 Schwinn Volare Restoration/Preservation

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle After Restoration / Preservation
Funny thing happened to my friend Dave, he went to go look at a Schwinn Paramount and came home with a Schwinn Volare.  The Schwinn Volare is my favorite of all bicycles and a dream bike of mine.  I have not come cross a reasonable Volare in 60-63 cm for myself yet.  The Volare is known as the Japanese Paramount with Dura Ace first generation components.  Schwinn was trying to fill a spot that was a little less expensive then the Paramount with what would be a little less nice (less nice as I can't say it a better way right now.) then the Paramount.  What the ended up doing was making a stunning bicycle that is very close to the Paramount and cut into the sales of the already dwindling sales of the Paramount.

I think the Volare is such a beautiful bicycle with the chrome lugs, chrome frame under the paint and the chrome stays.  The Dura Ace components are just plain wonderful  and I love it in either the pearlescent orange or the red.

The 1977 version comes with a Crane rear derailleur, Dura Ace crank, Dura Ace brake calipers and levers, Dura Ace front derailleur, Dura Ace shift levers, Dura Ace seat post and Dura Ace wheel hubs.  The saddle I can not remember what was original but I do know its not the Brooks Professional like the Paramount. 

Dave's Volare he found has seen some miles but at the same time the Volare was taken care of very well.  The one part of this Volare is its missing the original wheels.  It has a strange steel rimmed 27 inch wheel on the back and a sew up 700c front wheel that came of a Paramount track bike.  Also the Dura Ace seat post was replaced with a Campagnolo seat post, not the worst thing.  The Volare has been sitting in a garage for many years unused so there is a lot of dirt and dust and some of the paint surface has some etching from the years.  Under all the dirt though I believe there is an stunning example of a Schwinn Volare.  I can't wait to see it!!


Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Handlebars

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Brake Levers

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Dura Ace Brake Levers

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Stem & Handlebars

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Head Tube

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Front Dura Ace Brake Caliepr

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Front Trak Wheel

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Front Wheel Hub

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before -  Front Wheel Rim

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - SR Stem

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Dura Ace Headset

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Chrome Head Tube Lugs

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Chrome Head Tube Lug

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Reynolds 531 Fork

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Dura Ace Shift Levers

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Top Tube Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Down Tube Volare Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Replacement Campy Seat Post

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Seat Lug

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Drive Train

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Bottom Bracket

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Dura Ace Crank

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Dura Ace Front Derailleur

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Rear Dura Ace Brake Caliper

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Dura Ace Chain Stay Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Rear Crane Derailleur

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Wrong Wheel

Dave's 1977 Schwinn Volare Restoration/Preservation
Bicycle Before - Pedals

The frame is very dirty, after cleaning I found only a very few paint chips that only go to the primer level so very easy to fill.  The paint does have an etched finish from sitting so long in the dust.  I very carefully worked through a few polishing grits and found the paint to be almost perfect, just amazing!!  
Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Head Tube

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Head Tube

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Chrome Head Tube Lug

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Top Tube Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Down Tube Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Seat Lug

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Reynolds 531 Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Bottom Bracket

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Bottom Bracket

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Seat Stays

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Chain Stays

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Chrome Stays

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Drop Outs

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Rear

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Fork

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Chrome Fork Crown

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Fork

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Fork Chrome Blades

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Before - Fork

As I mentioned above the frame polished almost perfect, it is stunning!! The chrome also polished just beautifully!!  I love it!!  The decals are also in perfect shape except for the non-drive side fork blade decal, but those decals are available.  I couldn't be happier with the results!!


Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Head Tube

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Head Tube

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Chrome Lugs

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Top Tube Decals

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Down Tube Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Seat Lug

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Bottom Bracket

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Bottom Bracket

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Bottom Bracket


Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Chain Stays

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Reynolds Decal

Dave's 1977 Schwinn Volare Restoration/Preservation
Frame Polished - Chain Stays

The headset & bottom bracket are both Dura Ace, they are just wonderful components.  I cleaned the pieces and hand polished everything.  I am hand polishing everything because I want to keep the original surface finish, I just want to knock back some of the etching from the dirt and dust.  Bearings packed in new grease and everything spins perfect.  I love the photo of the completed headset with all that chrome!
Dave's 1977 Schwinn Volare Restoration/Preservation
Dura Ace Bottom Bracket & Headset - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Bottom Bracket & Headset - Polished

Dave's 1977 Schwinn Volare Restoration/PreservationHeadset Bearings - Packed

Dave's 1977 Schwinn Volare Restoration/PreservationPressing Headset Cups

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Headset Cups - Pressed

Dave's 1977 Schwinn Volare Restoration/PreservationHeadset - Complete - Stunning!!

Dave's 1977 Schwinn Volare Restoration/PreservationBottom Bracket Bearings - Packed

Dave's 1977 Schwinn Volare Restoration/PreservationBottom Bracket - Complete

Dave's 1977 Schwinn Volare Restoration/PreservationHeadset & Bottom Bracket - Complete

I did not disassemble the handlebars and stem, the original cloth handlebar tape was in such good shape it just needs cleaning.  If I removed everything I would loose the tape.  I polished everything by hand and everything turned out great. I cleaned the tape and the brake lever hoods and they look great.  The brake lever hoods are not perfect but I would take the patina every time over perfect.  I am very pleased with the results.

Dave's 1977 Schwinn Volare Restoration/PreservationHandlebars, Stem & Brake Levers - Before

Dave's 1977 Schwinn Volare Restoration/PreservationStem & Handlebars - Before

Dave's 1977 Schwinn Volare Restoration/PreservationStem - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Brake Levers - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Brake Levers - Before

Dave's 1977 Schwinn Volare Restoration/PreservationHandlebars, Stem & Brake Levers - Cleaned & Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationStem & Handlebars - Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Brake Levers - Cleaned & Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationStem, Handlebars & Brake Levers - Installed

Dave's 1977 Schwinn Volare Restoration/PreservationStem, Handlebars & Brake Levers - Installed

Dave's 1977 Schwinn Volare Restoration/PreservationStem - Installed

Dave's 1977 Schwinn Volare Restoration/PreservationStem, Handlebars & Brake Levers - Installed


I love the Dura Ace crank, the first generation.  It is just a perfect classic look.  At some point someone tried to paint in the grooves and flutes to match the bike.  The idea was very cool the execution was just not good.  I cleaned everything and most of the pint flaked off in the cleaning process, the rest of the paint removed with a little Acetone.  I love this crank installed, amazing!


Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Crank - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Crank - Paint Removed - Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Crank - Installed

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Crank - Installed
The original seat post is missing and so is the original saddle but the seller threw in a Brooks Professional from rough the same era.  I would take the Brooks every time over the original.  The brooks is perfect for the Volare, probably should have had one originally.  

The seat post that is on the Volare is a nice Campagnolo seat post but it is also an extremely frustrating seat post to adjust with to adjustment bolts on the top under the saddle, my big hands do not work well in there.  Some one along the line also cut the seat post way down with a hack saw, luckily at Dave's riding position a go amount still is in the seat tube.

The seat post and saddle look great installed!  I love it!

Dave's 1977 Schwinn Volare Restoration/PreservationCut Campy Seat Post

Dave's 1977 Schwinn Volare Restoration/PreservationStrangely Cut Campy Seat Post - Before 

Dave's 1977 Schwinn Volare Restoration/PreservationSeat Post Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationBrooks Professional Saddle

Dave's 1977 Schwinn Volare Restoration/PreservationBrooks Professional Saddle

Now we are getting to the really cool stuff, the Dura Ace front derailleur and the Crane rear derailleur.  Both where very dirty and had the etching from storage time.  The rear derailleur also had the red paint in the lettering area trying to match the frame color.  I cleaned the pieces and removed the red paint and hand polished everything.  The derailleurs turned out fantastic, they function so tight and smooth and look just amazing against that polished red paint, it doesn't get any better! 

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Front Derailleur - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Front Derailleur - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura ace Front Derailleur - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Front Derailleur - Exploded

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Front Derailleur - Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Front Derailleur - Complete

Dave's 1977 Schwinn Volare Restoration/PreservationFront Derailleur - Installed

Dave's 1977 Schwinn Volare Restoration/PreservationCrane Rear Derailleur - Before

Dave's 1977 Schwinn Volare Restoration/PreservationCrane Rear Derailleur - Before

Dave's 1977 Schwinn Volare Restoration/PreservationCrane Rear Derailleur - Before

Dave's 1977 Schwinn Volare Restoration/PreservationCrane Rear Derailleur - exploded

Dave's 1977 Schwinn Volare Restoration/PreservationCrane Rear Derailleur - Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationCrane Rear Derailleur - Complete

Dave's 1977 Schwinn Volare Restoration/PreservationDerailleurs - Complete

Dave's 1977 Schwinn Volare Restoration/PreservationCrane Rear Derailleur - Installed

I really like the Dura Ace brake calipers from the first generation.  I use them on my gravel grinder single speed, they work fantastic.  I disassembled the calipers and then cleaned and hand polished the pieces.  The calipers turned out just like new, what a look!  I wish I didn't forget to take a photo of the calipers installed.

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Brake Calipers - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Brake Calipers - Exploded

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Brake Calipers - Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Brake Calipers - Complete

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Rear Brake Caliper - Installed

I don't know how to exactly explain it but you know great friction shift levers from just the feel.  These Dura Ace shift levers have that feel.  I cleaned and hand polished the levers and the cable guide and then installed and lubricated the levers.  They work like butter and look like jewels.

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Shift Levers - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Shift Levers - Before

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Shift Levers - Before

Dave's 1977 Schwinn Volare Restoration/PreservationBottom Bracket Cable Guide - Before

Dave's 1977 Schwinn Volare Restoration/PreservationBottom Bracket Cable Guide - Before

Dave's 1977 Schwinn Volare Restoration/PreservationShift Levers & Cable Guide - Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Shift Levers - Installed

Dave's 1977 Schwinn Volare Restoration/PreservationDura Ace Shift Levers - Installed

Dave's 1977 Schwinn Volare Restoration/PreservationBottom Bracket Cable Guide - Installed

The pedals are still tight and spin like butter.  i removed the old toe clips as the leather was very brittle and then hand polished the pedals, they turned out fantastic.

Dave's 1977 Schwinn Volare Restoration/PreservationPedals - Before

Dave's 1977 Schwinn Volare Restoration/PreservationPedals - Hand Polished

Dave's 1977 Schwinn Volare Restoration/PreservationPedals - Installed

Below is a photo of the main components complete, next is to wire the bike and wait on the wheels.

Dave's 1977 Schwinn Volare Restoration/PreservationMain Components - Complete

New cables are being installed but the original cable housings are going to be used.  I cleaned the housings and then lubricated the housings.  With the new cables installed the housings work fine and look great.  
Dave's 1977 Schwinn Volare Restoration/PreservationNew Cables

Dave's 1977 Schwinn Volare Restoration/PreservationBicycle Wired

Dave's 1977 Schwinn Volare Restoration/PreservationBicycle - Wired

Dave's 1977 Schwinn Volare Restoration/PreservationBicycle - Wired

Dave's 1977 Schwinn Volare Restoration/PreservationBicycle - Wired

Dave's 1977 Schwinn Volare Restoration/PreservationBicycle Waiting on Wheels

Dave has some nice wheels for the Volare, they are off of a Panasonic DX5000 from the 1980's.  I know this because I took them off a damaged Panasonic DX5000 frame and restored them and sold them to Dave.  They are really nice wheels and Dave has 28 mm Ruffy Tuffy tires installed.

The Pie plate I think is original and maybe the freewheel??  I know the 1978 version of the Volare had a Dura Ace Freewheel but the 1977 version had a few things different.  The freewheel is an Italian freewheel and you can really see the quality and the feel of quality in it.  Installed the wheels actually go very well with the Volare, I think only the original wheels would be better.

Dave's 1977 Schwinn Volare Restoration/PreservationFreewheel & Pie Plate

Dave's 1977 Schwinn Volare Restoration/PreservationBeautiful Italian Freewheel

Dave's 1977 Schwinn Volare Restoration/PreservationDave's Replacement Wheels from a Panasonic 5000

Dave's 1977 Schwinn Volare Restoration/PreservationDave's Replacement Front Wheel
From a Panasonic 5000

Dave's 1977 Schwinn Volare Restoration/PreservationDave's Replacement Rear Wheel
From a Panasonic 5000

Dave's 1977 Schwinn Volare Restoration/PreservationDrive Train - Complete

The plan was to complete the Volare Sunday morning when Dave brought the new wheels up and then we would go riding.  Well we got the wheels on but the monsoon season we have going here in Northern Illinois and Southern Wisconsin decided to continue.  It rained all morning and then when I went riding in the late afternoon everything was still very wet and muddy.  Needless to say we did not get out riding the Volare and I did not get nice outdoor photos before the Volare went home and the rain stopped.

I wish i could have gotten a few outdoor photos because the Volare turned out almost mint.  It is just an amazing bicycle to start with and when brought back like this it is my favorite bike ever.  I am still looking for one in my size.  I do have an orange 1978 one in 54 cm that someone turned into a single speed.  It is a minimum 4 cm to small for me and I am still looking for the missing components at a reasonable price.  

Dave got to ride the Volare yesterday late afternoon down where he lives and said it road just perfect.  I is fast, nimble, light and solid and best off all it fit perfect.  He also sent me a photo of the Volare in its new spot hanging in his bike area.  What a stunning bike!!

Dave's 1977 Schwinn Volare Restoration/PreservationBicycle - Complete
Dave's 1977 Schwinn Volare Restoration/PreservationBicycle After in Garage - Pouring Rain

Dave's 1977 Schwinn Volare Restoration/PreservationBicycle After - Dave's Bike Room


2 comments:

  1. Wow what a sweet ride; 531 tubes, lots of chrome, Dura-ace components etc. Did you have the Dean Martin tune of the same name playing as you did the work?

    ReplyDelete
  2. Nicely done. I only recently found your blog. Very impressed with the level of your work.

    ReplyDelete