What do you do when the cones of your wheel worn out (worn out = show signs of a pit/groove from the bearings resulting the hub to not spin smoothly)? Your either replace the cones with new ones, or as many people do nowadays, buy a new wheel! The problem is, that cones are not that hard to pit, especially if if you ride often on a rough terrain or if you ride a loaded bike. Few weeks ago, a friend of a friend gave me for free his expensive wheels, because he bought new ones after he noticed the worn out cone symptom (problematic wheel spinning)!
The factors that causes hub cones to pit are many, and although you can prolong their lives by maintaining them regularly, sooner or later you will have to buy new ones, or buy a new wheel! Before you do that, please continue reading!
Giannis‘ creative thinking found an easy and free solution by asking the radical question “why not repair them?”. He proved that this can be done with only a drill, a piece of sandpaper, a nail and a dremel grinding bit. He even put the repaired cones to the test for a year (about 14.000 kms) and the cones seem to be holding up perfectly!
Here is how he did it: