Bicycle Mechanics - Damaged aluminum frame

I bought an early 90s Cannondale aluminum road frame for $10 last night. It has a broken dropout (derailer-related injury) that's basically snapped off right where it holds the axle. Is there any possible way to repair this, say by welding the broken-off piece of dropout back on, or is it time to junk this thing?

I don't feel too bad if it's just junk, because I got a nice stem, bars, brake levers, shifters, and fork out of it, so what the heck...

I bought an early 90s Cannondale aluminum road frame for $10 last night. It has a broken dropout (derailer-related injury) that's basically snapped off right where it holds the axle. Is there any possible way to repair this, say by welding the broken-off piece of dropout back on, or is it time to junk this thing?

I don't feel too bad if it's just junk, because I got a nice stem, bars, brake levers, shifters, and fork out of it, so what the heck...Someone else here had similar problem with a broken hanger.LBS gave him a Cdale replaceable hanger and he disappeared with a file to try and cob together a repair.The broken dropout is even more serious,and welding isn't an option with cdale 6061 because of the requuired heat treatment.

Thanks sydney! If I understand correctly, a heat-treated frame cannot be rewelded because the heat of welding will weaken the heat treatment?

Thanks sydney! If I understand correctly, a heat-treated frame cannot be rewelded because the heat of welding will weaken the heat treatment?It depends on the specific alloy and heattreatment.6061 requires a high temperature quenchhing.

900 deg peak temp sustained for 3 hrs then stepped down in process. Not something easy to do for a normal person's means.
There are some other options, one of which is to get a deraileur mount plate. Not like the modern replacable type, but the older design that is retained with a bolt and the axle slot. It would still require some creatiive shaping, but I have done the refit several times.

From 1991 on, Cannondale uses a replacable hanger that is also the lower half of the dropout. I had to replace mine last summer on a 2.8 R500 after a shifting problem devloped and the rear derailluer shifted into the spokes and snapped off the hanger. I thought the frame was hosed until I took it to a Cannondale shop, who promptly replaced the hanger.

1. Check out the replacement hangar option - maybe one exists for this frame, or maybe you can cut and file the current one to make an old Can replaceable dropout fit. Could be cheap, but might take time.
2. New Shimano Hone and Saint rear deraillers clamp onto the rear axle (must be from the groupset), and don't require derailler hangers. Expensive - new rear derailler, new rear hub, new wheel build.
3. Turn it into a kickin singlespeed - no need for a derailler. I'd do that - it's super sheap, and so much fun!

Thanks for all the advice. I'm not sure I was clear in my description of the damage: it's NOT just the derailer hanger that has broken! The entire dropout from about the 9 o'clock position on the part that holds the axle has broken off.

I guess this isn't something that could be repaired without rewelding the frame. It's no great loss to me, but a pity because it's such a cool-looking frame and I was told by the previous owner that it made a great ride.

The frame has a lifetime warranty; see if they will replace it.

lifetime warranty usually only applies to the original owner....

It has a broken dropout (derailer-related injury) that's basically snapped off right where it holds the axle. Is there any possible way to repair this...

Piece of cake! I was the guy with the problem - fixed it easily - my frame's now on e-Bay (it was too large). See the repair (and the replacement hanger from Cannondale) here:

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&rd=1&item=7143438550&ssPageName=STRK:MESE:IT

When you install the replacement, be sure to THIN the existing rear plate from the outside, and do it WITHOUT making any abrupt "shoulders" in the aluminum that can become stress-break points. With power tools, this is about a 15 minute fix! A hack saw, a portable drill, and some abrasives from the local store are all you need in addition to Cannondale's neat hanger.

Good luck!

Piece of cake! I was the guy with the problem - fixed it easily - my frame's now on e-Bay (it was too large). See the repair (and the replacement hanger from Cannondale) here:

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&rd=1&item=7143438550&ssPageName=STRK:MESE:IT

When you install the replacement, be sure to THIN the existing rear plate from the outside, and do it WITHOUT making any abrupt "shoulders" in the aluminum that can become stress-break points. With power tools, this is about a 15 minute fix! A hack saw, a portable drill, and some abrasives from the local store are all you need in addition to Cannondale's neat hanger.

Good luck!
Holy geez, man! You're my new hero :) Your frame looks very similar to mine. Do you have any information on that replacement hanger? I couldn't find it anywhere by googling Cannondale's site. Good luck with the sale.

Do you have any information on that replacement hanger? I couldn't find it anywhere by googling Cannondale's site. Good luck with the sale.

My LBS had several in stock - in fact, once the LBS owner saw the work done on my frame, he gave me another Cannondale frame with the same malady, another Cannondale hanger, and asked me to fix his frame & e-Bay it for him on halves. It probably isn't worth my time, but since the owner has been good to me..

If you want, I'll ask if he has another hanger in stock. 37 cents plus the price of the hanger & I'll mail it to you. Good luck with your frame!

If you want, I'll ask if he has another hanger in stock. 37 cents plus the price of the hanger & I'll mail it to you. Good luck with your frame!
There is a local Cannondale dealer, so I will bring it to them. But I may end up PMing you about that hanger. Thanks for the awesomely timed advice!

Thanks for the awesomely timed advice!

My pleasure. The folks here on bikeforums have been great for me & it's a pleasure to be able to return something.

Gotta love a happy ending :-)
D

lifetime warranty usually only applies to the original owner....
I know for a fact that Crack-n-fail's warranty is original owner only

I know for a fact that Crack-n-fail's warranty is original owner only
I was wondering when we'd hear from you :)

I was wondering when we'd hear from you :)
You should have known you stood a fair chance of me popping my head in

I know for a fact that Crack-n-fail's warranty is original owner only

Enough with the "Crack-n-fail" already! Make fun of the Head****, but not the frames. :mad:

Enough with the "Crack-n-fail" already! Make fun of the Head****, but not the frames. :mad:
Package deal sorry

I forgot, what do you ride?

Hey Raiyn I got those emails thanks.

Enough with the "Crack-n-fail" already! Make fun of the Head****, but not the frames. :mad:

Not to stir you up, but this thread IS about a broken frame..................

Hey Raiyn I got those emails thanks.
Good deal.


Ex, I'm not picking on C'dale to get at you personally, I just despise them. Althougth they do rank higher in my opinion than the "New Schwinn"
Different strokes for different folks just don't have one on me based on my opinion

Not to stir you up, but this thread IS about a broken frame..................

It's about a broken dropout. You can't blame Cannondale for that. When I lived in the states, there were 3 Cannondale dealers nearby, and we bought 5 bikes between them. Never had a problem, never heard of anyone in our clubs having problems with frame failure. Those days are over, time to move on.

Original poster's problem appears to have been solved.

Why don't you guys take yours off-list and let this thread drop out of sight (pun partly intended).

ok.