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@number6
1 up - welded cogs - snapped
2 up - free hub jammed with nails - lob sided splines - a problem i'd suspected might happen
3 up - free hub jammed with nails (revised) got it central and fixed but had lash (quite stiff and short travel - but lash never the less - unaccepetable)
4 up (what i should have done after the welded cogs incident) 'JB weld' (6.95 gbp from local car shop )in the free hub - set overnight. - success
2 S3X cogs and a 12t single speed kit sorted the rest. spacing is easier (you space at the rear spline instead of at the crank plus messing with the cups and cones which the welded cogs method demanded )- changing the cogs if you want to is easier (when i get that 35t ring)
the first road test proves it to be zero lash whilst being completely tolerant of some viscous skids in the dry on 28mm tyres with my weight far back :
links for anyone who wanta to give it a go .
this is useful, i'd never been inside a freehub 4 days ago (tip: the bearing cup is counter threaded and can be knocked with hammer and screwdriver - you don't need the special tool shown)
http://www.parktool.com/repair/readhowto.asp?id=45
this is the method - told here for a freewheel - but they are pretty similar inside (good tip : twist the unit clockwise to get pawls to engage in the driving position before it sets)
http://scoplaw.blogs.com/scoplaw/2004/04/how_to_make_a_f.html
added some cages, lights, speedo etc - ready for the hills now
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