Join Date: Apr 2009
Location: New Rochelle, NY
Bikes: too many bikes from 1967 10s (5x2)Frejus to a Sumitomo Ti/Chorus aluminum 10s (10x2), plus one non-susp mtn bike I use as my commuter
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Didn't you ask this on another forum? Or didn't you like the answers you got.
Anyway, here's mine again.
Based on a similar application not involving a bike.
Start by drilling a hole of the right diameter in the right place* to form the end of the slot. Use a coping saw, or hack saw to connect the current slot's end to the hole top and bottom, slightly narrower than desired (how close you work depends on your skill and confidence in sawing to a line). Finish by filing the slot to final dimension.
* the location of the hole is critical because it's important that the dropout slots are parallel and at the same height. Otherwise your rear wheel won't be vertical. Don't measure twice, measure 3-4 times and be sure. If you're not sure of the accuracy of your measurements you can file the top of the slot on the lower side using a wheel you know to be true and dished correctly to check until it's exact. later you'll have to remember to always install the wheel on the ground, so gravity ensures that the top of the slot rests on the axle.
An ounce of diagnosis is worth a pound of cure.
“Never argue with an idiot. He will only bring you down to his level and beat you with experience.”, George Carlin
“One accurate measurement is worth a thousand expert opinions”
- Adm Grace Murray Hopper - USN
WARNING, I'm from New York. Thin skinned people should maintain safe distance