VAR CD-03600 User manual
Espace Eiffel - Lot D6
19 et 21, Avenue Gustave Eiel
28630 Gellainville - FRANCE
+33 2 37 33 37 10
EN CD-03600
HEAD TUBE AND BOTTOM BRACKET SHELL
REAMING & FACING SET
VAR thanks you for purchasing CD-03600, specially designed for head tubes and
unthreaded bottom bracket shells reaming and facing, before headset or pressed-in
bottom bracket installation .
The support can be purchased without cutter (CD-03600) or with a 44mm headtube
cutter t(CD-03600-44).
Please read this manual carefully before each use.
The set contains :
- 1 headset and bottom bracket shell cutting tool support
- 1 tapered pilot
- 1 bearing ring
- 1 compression spring
- 1 push ring
Recommendations
CD-03600 and its cutting tools are precision tools that have to be used and stored
with care, avoiding shocks, falls and mistreatments.
The cutting tools must be cleaned after each use, with a lubed cloth or an anti-rust
solution.
Never use traditional lubricants, which are not suitable in metal machining and
lower the machining quality and your cutting tools lifespan.
1/4
NAME STANDARD FRAME DIAMETER
(mm) REFERENCE
BB30
Press Fit
Press Fit 30
Traditional
Zero Stack
Integrated
BB30
PF
PF30
EC34
EC49
ZS44
ZS56
IS41
Cane Creek
IS42
Campagnolo
IS52
42
41
46
33.90 - 33.95
49.57 - 49.61
43.95 - 44.00
55.90 - 56.00
41.10 - 41.20
41.95 - 42.05
52.05 - 52.15
CD-03623-BB30
CD-03623-PF
CD-03623-PF30
CD-03623-33.8
CD-03623-49.55
CD-03623-44
CD-03623-55.95
CD-03621-41.15
CD-03622-41.15
CD-03621-41.95
CD-03622-41.95
CD-03623-52.10
Reaming and facing cutter selection
Important information
IS41 and IS42 headtubes need two different cutting tools (CD-03621 and CD-03622),
because the lower bearings are set deeper in the headtube.
CD-03621 references must be used on the lower section of headtubes, while
CD-03622 references must be used on the upper section of headtubes.
Precautions of use
Frame machining is not a common operation, as much for the frame as for the
operator.
The frame will be correctly secured on a repair stand and the working zones well
lubricated with cutting fluid.
The operator will wear VAR AP-94300 protection gloves in order to avoid any cuts or
pinches and VAR AP-94500 safety glasses to avoid any cutting fluid or metallic
shavings tprojection.
2/4
Instructions
1. For a perferct stability, install the frame on a VAR PR-90100 or VAR PR-90200
repair stand.
2. Ensure the right reaming and facing cutter tools, so the selection matches
your frame dimensions. Please refer to the previous page table.
3. Start by machining the headtube lower section. Rotate the frame so the
lower section faces upwards.
4. Place the lower reaming and facing cutter on top of the support and then
slide the assembly through the headtube. The cutter is held on its axle by a
ball-adjustable screw.
Next, install the tapered pilot in the opposite side with the bearing ring, the
compression spring and the push ring.
5. Spray generously and regularly the cutter tool and the machined zone with
VAR CD-77000 cutting fluid, in order to perform a qualitative machining and
preserve your tools’ lifespan.
Pull the push ring up, the spring and the bearing ring so the tapered pilot gets into
position inside the headtube.
6. Rotate the handles in clockwise direction only. If you rotate the handles in a
counterclockwise direction, you are causing damages to your cutting tools.
During the machining, the pressure can be increased by tightening the push ring
progressively. Continue the operation until the cutting tool touches the headtube
surface in order to obtain a perfectly planar surface, without any trace of painting.
The upper and lower headtube surfaces must be rigorously coplanar.
7. Release the spring tension by unthreading the push ring. Then lower the
bearing ring, the spring and the tapered pilot to check the 45° reaming quality and
the headtube surface machining.
If the reaming / machining quality is not satisfying, replace the rings with the pilot
and operate for one or two more rotations.
8. Repeat the operations listed above on the upper section of the headtube,
using the appropriate reaming and facing cutter and the tapered pilot.
The reaming depth being more important on the lower section of the headtube, it
offers an excellent housing to the tapered pilot for a well-alignated machining of the
upper section of the headtube.
9. After machining, thoroughly clean the headtube with a clean cloth and VAR
NL-75300 degreaser in order to remove any remaining used cutting fluid and
metallic shavings.
This will ensure you a perfect assembly, adjustment and functionning headset.
N.B : These instructions also suit non-threaded bottom bracket shells.
3/4
4/4
Illustrations
Cutting tool support with
handles
Reaming and facing tool
Tapered pilot
Bearing ring
Compression spring
Push ring
Other VAR Tools manuals
