The bearing cage was put in backwards. Thus instead of the force going from the cone through the balls to the outer race, it was going from the cone through the cage to the outer race.
On my bikes with cup and cone bottom brackets, I use loose balls - one more ball than in the cage, so I never have worry about messing up; and stiffer and stronger.
More full proof and simpler, though more expensive solution is a sealed BB, like a Shimano UN54
Nigel
I wouldn't bother with cup and cone bottom brackets these days, they're a pain to adjust, there's no seals, so they get dirt and water in them and don't seem to last.
Like Nigel says, get a Shimano UN54, they aren't expensive, they're easy to fit, they last for ages and need absolutely no maintenance.
Yep 10-4 to getting a UN54 sealed BB.
As per your set up you can try and just use plain bearings without the cage, you can get more bearings in that way.
Never Give Up!!!
Something else I wanted to throw in is that the spindle is NOT even!!! One side is longer then the other. It shows in one of Alex's videos that one of side of the spindle is longer from the bearing race to the end on the drive side (side with the chain)! Best way to tell this is to measure from the bearing race out to the end on both sides.
If this is case then your almost assured to smash the cage on the bearings on both sides.
Good maintenance to your Bike, can make it like the wheels are, true and smooth!
10-4 to what Dave said there should be a space about the width of one ball.
1FJef did you put lots of grease in when you reassembled your BB? The grease should hold the balls from rattling around freely. Lots of marine grade waterproof grease is what I use. Bel Ray is good, I use it in my motorcycles too.
Never Give Up!!!
Good point Nigel. Bearings should not roll around freely or there would be play. They need to be preloaded. As per size difference between lots , hmmm, never had problems with that but possible headache.
Never Give Up!!!
I buy bearings in bulk from McMaster-Carr.
I believe then that it would be a wear issue as there is different play with the pedals vertical (less) versus horizontal (more). Good call guys.
It is a used bike.
Every high mileage one piece crankset I've checked has had more play with the pedals at 3 & 9 o'clock.
I suspect that as they wear, they are not adjusted often enough resulting in even more severe wear.
The readjustment of the BB I was referring to was involving very old worn primitive one piece cranksets.
So the cage ring is toward the cone (spindle) & the exposed balls are outwards towards the cups, right?
What kind of noise, surely not a crackling popping?