Restoring & Modifying a 1973 Schwinn Jr. Varsity (24”) — Need a Real Human Sounding Board!

I ’m in the middle of restoring/modifying my favorite frame: a 1973 Schwinn Jr. Varsity with 24” wheels — perfect fit for me at 5’3”. I’ve been learning everything by doing. It’s low stakes since these don’t tend to be highly valued (I literally got this one for $20).

I’ve restored another Jr. Varsity before (turned it single speed with 9” rise handlebars), and a Suburban that I left intact. This time, I’m taking things a few steps further.

So far, I’ve fully dismantled the bike, rust-treated it, stripped the paint, sanded, and refinished it using Spray.Bike paint (primer + color). I’m now considering converting it into a cruiser and rebuilding the wheels myself using the original rims. Would it be a waste to do that? Alternatively, I might just turn it into another single speed.

Here’s where I need help from actual people (no offense, ChatGPT):

I plan to use the original front hub (Schwinn Approved 4-73, Made in France)

And swap in a Bendix 70 coaster hub from a 1970s Schwinn Breeze for the rear

Front Wheel – 2-cross:

I tried reusing the original spokes with new 14G nipples in a 2-cross pattern, but they poked through the rim — I’m not sure why. So I’m starting fresh and want to calculate accurate spoke lengths.

Rear Wheel – 1-cross:

Why 1-cross? It seems to be standard for the Bendix 70 with 28 spokes and a 24” rim — and visually confirmed on the Breeze.

🧮 ERD & Hub Specs:

Measured ERD: 537 mm across opposite spoke holes

→ Adding 2 mm per nipple seat → ERD = 541 mm

Front hub: Flange diameter 33 mm, hub shell width 81 mm

→ Center to flange (assumed symmetrical): 40.5 mm

Rear hub (Bendix 70): Flange diameter 57 mm

→ Center to flange: 34 mm (L), 17 mm (R)

📏 Calculated Spoke Lengths:

Front: 264 mm (both sides, 2-cross)

Rear: 245 mm (left), 243 mm (right), 1-cross

Would love feedback from anyone who’s built similar setups, used these rims, or dealt with ERD mismatch on vintage Schwinns. I’d also really appreciate confirmation (or correction) on those spoke lengths before I order.

Thanks in advance — I’m finally out of the ChatGPT echo chamber and excited to talk to real people about this!