Cycling UK Forum

I have a 1962 5 speed Merlin Racing cycle, and have bust a spoke on the cassette side of the rear wheel. I need to remove the cassette before I can fit a new spoke. Has anyone got any ideas how this can be removed/are special tools required.

What you have is a freewheel block, not a cassette. The freewheel mechanism is in the block and screws off with the sprockets. The removal tool you need depends on the type of freewheel. If you could post a picture that would help, or at least tell us the make/model of the block.

The block does not have a name/type. I have a picture of it, but not sure how to upload.

Whatever type/make of block you have, it should have one of three different fittings.

Two peg
Four peg
Multi slot

You are still able to buy all three types, but if my info isn't quite right, there may be other sorts! If you take your wheel off and look at the front of the block, you should see what type you have.

You need to go to a decent bike shop or purchase on line. SJS have a selection:
http://www.sjscycles.co.uk/tools-casset ... g1/#page=1
Though I see they don't do the Two peg one.

Once you got the right tool, push it in and fit a spanner to the flats and try and unscrew it anticlockwise. It will be damned tight! Often, it's best to put the tool in a vice vertically and fit the wheel onto it, then turn the wheel. If it comes ok, it will release with a bang!

Hopefully, you'll be ok, but it's not an easy thing to do.

Yes, tight! My 1984 Raleigh had a Suntour screw on and five years ago I tried to remove it. The beggar would not unscrew, even with a 2m lever added. Although the hub moved quite a long way in relation to the rim!

Trust my bike to be awkward, the block has 9 slots - is this multi slot? The comments regarding going to a good bike shop, are a joke in my area (Darlington)
- nobody wants to touch a 50 year old bike. I rang a bloke at Redcar (East Coast Cycles) explained my problem, was told to bring it down (25 miles) - when I went into the shop, he took one look at the wheel and said he couldn't do it. Ah well, I had a pleasant afternoon at the seaside! It feels like I am being forced into buying a new bike, by default.

My LBS are always very helpful with things like that and don't usuallly charge if you are buying something. Bit far for you to come to Somerset though. Might be worth ringing Spa Cycles in Harrogate. Top notch wheelbuilders They will probably sort it if you send the wheel to them. Also, of course Paul Hewitt amongst others.

There's some info here about freewheel removal:

http://www.sheldonbrown.com/freewheels.html#remove

Unfortunately, that only shows some fairly recent models of remover; in the heyday of the freewheel there were many more. If you want to preserve the freewheel to use it again, the appropriate remover is the the only option. If the make isn't stamped on, then all I can think of is showing somebody who might help eg right sort of bike shop, or a cycling contemporary of your freewheel (who may even have the correct remover.) If you can't show somebody in person, I can't see much alternative to a pic on here.

If you aren't bothered about preserving the freewheel (and buying a replacement may be easier than tracking down the right remover if it's not a current model) then the Sheldon Brown stuff I have linked to includes a section on removal by destruction.

One spoke has gone....all the others are fatigued.
Destroy and remove the existing block, see Sheldon.
Buy a new block that takes a splined, Shimano type remover. Now you will be able to remove the block whenever you like.
The 2 dog, 4 dog, etc. removers were always a joke, only good for breaking and skinning your knuckles. There was never enough contact surface for them to work reliably.

If your really desperate buy a new wheel and cassette.

Given the age of the bike, 40-50 years of riding will make the freewheel very tight oon the hub, specially if it was fitted dry, no grease. The easiest solution ans mentioned previously will be anew wheel and freewheel.

New wheel may be difficult as the old one will be 27". Yes, you can fit a 700c, but they look stupid IMHO in a frame built for 27".

Best option is to try and get the freewheel off, but failing that pull it apart and then try and get the inner bit off - usually much easier as you can use brute force.

Then, re-build the wheel with new spokes and fit a new freewheel.

Byercycles sell 27" wheels they are £30 plus postage.
They also sell 5 speed Freewheels as well.
Decathlon also sell 27" wheels I think.

Where are you based?

A new wheel has to match the "over lock nut" OLN dimension of the frame/existing wheel. Illustration from Sheldon, who being American, calls it OLD. http://www.sheldonbrown.com/gloss_n-o.html#old illustration is modern cassette hub, you need screw on. You can spring the frame for a hub say 5mm wider.

Also needs spacing for 5 speed, if you use a modern hub spaced for 7 or 8 speed the wheel dish will be excessive.

Chances are your hub will be 120 mm wide (or even less). It does not make much sense to use modern wheels in such frames. Have a look at the Shimano style freewheels, and see if they are the same standard as what you have. If it is, removing the freewheel should be relatively easy. If it is not, or if it does not come off, remove it by destruction. After that, get the wheel rebuilt. Many say that 27 inch wheels are not practical, but that is nonsense. Rims are still made, and so are quality tyres such as the Panaracer Pasela or the Conti Ultragatorskin.
Willem