The broken saddletube was not something the local bike shop could mend, or any of the bike shops in Salisbury. None of them build or repair frames, they just assemble bikes from components. The nearest frame-builders said that they would need the bike, dismantled right down to just the frame, and that the replacement tube would cost £100; they couldn’t tell me what it would cost to do the work, and I also had to consider the cost of getting to and from them on two separate journeys..
The Cheltenham Pedersen was built from Reynolds 531 tubing. This is a specialised tubing first produced in the late 1930’s for aircraft production, then was adopted by the bicycle manufacturers, motorcycle manufacturers, and even for the space-frames of the post-war Formula One Grand Prix cars before carbon monocoquestook over. It is no longer kept in stock, but can be made to order.
A peculiarity of 531 tubing is that is cannot be brazed using the usual brass or bronze alloys, but has to be silver-soldered at a much lower temperature. I was quite happy to learn how to silver-solder, but wanted to practice on some tubing first to make sure that I could get strong joints without overheating them tube or creating too sharp a temperature gradient. Try as I might, I couldn’t find any offcuts of 531 tubing on which to practice. I haunted the specialist car repair companies near me, because I knew that the Jaguar E-type used 531 tubing in the front subframe, but nobody had worked on one of them for years, and they just didn’t turn up with front-end damage any more.
I grew tired of riding Albert Ross around with the wooden splint lashed between the two saddle tubes, and decided there was an alternative. Half of the tube, from the bottom bracket to the small bridge tube, was perfectly sound, and I felt that, since there could be little flexing at this point due to the stiffening action of the bridge tube, a butt-joint with an internal sleeve could be feasible. However, the fracture had occurred just above the small bridge tubing, so close to it that I doubted that any butt-brazed repair would be possible, because the heat required to join the two pieces of tube together would soften the already-soldered bridge tube. I could see why the Bristol frame-builders had fitted a complete new tube when they had repaired a similarly-damaged Pedersen. But, there were excellent epoxy adhesives around which required no heat at all.
I used my old lathe to turn down a two-inch piece of steel bush so that it was a tight fit inside the two broken ends, chamfered the ends of it so that there could be no chance of sharp-edge fractures where the outer tubes would continue beyond the bush, removed the bottom bracket and stuffed cotton wool into the hole to prevent any stray adhesive dribbling down into the threads, and used JB Weld to glue the piece of tube inside the two halves of the saddle post, keeping them firmly tensioned into the correct alignment. I had to wait at least 24 hours to allow a firm cure, and in fact managed to hold off from rushing over to the workshop when the 25th hour commenced, leaving it 36 hours before I refitted the bottom bracket, cranks and saddle, and went out for a ride.
I have now ridden Albert Ross around the outskirts of Newcastle for three days, up and down the hills around Hadrian’s Wall, and around several of the horribly rough tarmac lanes and dirt Ox-drove roads in Wiltshire, and the repair seems to be holding. As insurance, though, I still have the wooden splint lashed to the rear carrier with enough twine to be able to get home again should the adhesive ever fail. But so far, it looks as though it will indeed live up to the manufacturer’s claims.





