The Lunch Project

Restoring a 90s Kona Hahanna

First, let me explain how we got to this state of obsession with over-caffeinated jitters. Recently I found myself on the Annual Bike House Whānau Rat Ride, where team members pedal out to the beach on restored 90's rat bikes for an evening of fish & chips and sketchy first descents. Seeing everyone's creative restorations and having the best time roaming through the secret corners of Ōtepoti was such a blast!

The rat ride got me inspired to create and build something of my own.

So, there I was on my lunch break a few weeks back, searching the world wide web for a deal on an old 90's mountain bike. There were some crusty gems out there, but nothing caught my eye, until this stunning 1999 Kona Hahanna got me spitting out my mediocre flat white with excitement. Kona to me is like a 'Nokia 3310'... reliable, durable and built to last!

In the pantheon of mountain biking legends, the Kona brand of the 1990s holds a special, almost mythical place. Known for their distinctive geometry, iconic steel frames, and bulletproof components, these bikes were a benchmark of performance and style.

For myself, restoring a vintage Kona is more than a simple repair; it is an act of historical preservation and a deep dive into the golden age of the sport. The process is a rewarding journey that transforms a forgotten relic into a cherished, rideable masterpiece, celebrating the enduring quality of its design. 

I remember messaging my partner after finding this Kona Hahanna.

"Hey babe, look at what I just found (sent with a photo)! This is going to be my next creative art project. I'm going to work on it with Sam during our lunch breaks in the workshop so he can help me improve my mechanical skills."

She replied: "Is this your way of telling me you just got another bike?"

"Well, some call it bike. Some call it art... and if its a Kona it's called lifestlye babe!"

She laughed, but I could tell she was thrilled that I'd found a way to combine two of my passions - biking and art - into one project.

The restoration begins with a meticulous assessment. More often than not a bike in the same era as this Kona are often found in a state of disrepair, with rust, seized parts, and worn-out components all telling a story of neglect. 

The first task was to complete a careful disassembly. Every bolt, cable, and bearing was removed, cataloged, and cleaned. This stage was crucial, as it revealed the true condition of the frame and parts. The famous tange steel frame, often the heart of these Konas, was inspected for cracks and dents. Once the frame was stripped bare, it was thoroughly cleaned and polished, its original paint and decals carefully preserved and meticulously touched up to capture its former glory.

The real challenge and joy of the restoration lies in sourcing and restoring the components. The goal was to use period-correct parts to maintain the bike's authenticity. This meant hunting for an original Kona saddle and a unique steel handlebar. Sometimes, parts can be refurbished; a deep clean with elbow grease and I was able to bring a tired Project Two fork back to life, and a thorough polish made the crankset gleam again. The balance between finding original parts and using modern, but sympathetic, alternatives is a key decision, dictated by the bike's intended use and my vision for purist sensibilities. 

With all components restored or replaced, the final and most satisfying stage is reassembly. The process is a reverse of the disassembly, with each part being greased, installed, and carefully torqued. New cables and housing are routed cleanly, and the V-brakes are meticulously adjusted. The gears are indexed, ensuring crisp and precise shifting, and the chain is given a fresh coat of lube. This is the moment the bike takes its final form, not as a collection of parts, but as a cohesive, functional machine ready for the trail. The first ride after a restoration is a special moment, a tangible connection to the past where the frames unique flex and the satisfying clunk of the derailleur brings the legend back to life.

Ultimately, the restoration of my 1999 Kona Hahanna is a labor of love. A testament to a lot of hardwork, coffee, endless creativity, silly questions and not being afraid of making mistakes. The finished bike is more than just a means of transport; it is a piece of living history, a faithful companion reborn and ready for new adventures. 

Hei Hei click here if you want to have your own Process of art making... Dew it!!!