Kevin Mark Klughart


Patent Attorney / Engineer


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I recently refurbished my bicycle, a vintage 1984 Trek 660.  This bike has been a faithful companion over the years, with countless miles of use, through training in the Texas heat and some Triathlon use as well. Recently, however, the old girl started slipping gears, and it seemed that every time I went out I got a flat tire.  My wife suggested that I buy a new bicycle for my 50th birthday, but after looking at several models really didn't see anything that interested me.

The solution was to strip down the Trek frame to bare metal, sand blast off all the paint, prime it and repaint with a paint job that suited my tastes.  In doing this I also found a small crack in the frame that I repaired with a TIG weld.  Once the frame was done, I replaced the wheels (Campy Zonda), rear cassette (Campy 10 speed), bottom bracket (Campy), brakes, front/rear shifters (Campy comp triple), chain (Campy), cables, and water bottles/holders.  The result is a bike costing about what a moderately priced road bike would cost, but with top-of-the-line Campy components.  The bike drives like a dream - better than original!  Parts were obtained from who provided great pre-sales support for the rebuild.

Three minor machining items had to be fabbed for this refurb.  First, the grease caps for the petals had come lose and exposed the bearings, so I had to disassemble them, regrease, reassemble, and machine two new aluminum end-caps for grease retention.  These were 22mm x 1.0mm, something that my Jet Lathe handled with no problem.  I also had occasion to need a puller to remove the crank from the bottom bracket.  This required a steel cylinder to be threaded to 22mm x 1.0mm to fit into the crank and then be threaded with a 7/16 grade 8 bolt to apply force to the bottom bracket and remove the press-fit Campy crank.  While they make commercial tools to do this, I didn't have one, but with the Jet Lathe it wasn't hard to fab one up.  

Finally, the frame tubing on the Trek was about 1.125 inches, and the front shifter needed a 1.250 inch diameter clamping diameter, so I ended up turning a 6061 retaining sleeve to interface the Campy shifter to the Trek frame.  I'm pleased with this adapter - it looks stock!

The result of all this work was a bicycle better than anything I had ever used before!  I can't say enough about the Campy components, wheels, etc. and the overall ride and feel of this bike.  It is TIGHT and TRUE and a joy to ride!  Thank you Jean for a GREAT 50th birthday present!



Contact Information:

Kevin Mark Klughart

Registered Patent Attorney, USPTO

3825 Leisure Lane, Denton, TX 76210-5589

tel: 800-353-1211 / 940-320-0580  -  fax 940-320-0581   email  -  web

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