A rack mount eyelet on my 2009 Kona Sutra touring frame broke off. I'd like to not just fix it but improve if possible, the original Kona design is embarrassingly weak. I'd like to remove the remaining eyelet as well and attach a more substantial tabs with larger holes, M6 - I believe it's M5 right now.
Also, while at it: the frame has only one eyelet on each side, I'd like to have two, like my other bikes, one for the fender struts as I don't like to mount those under the rack tabs.
I have no welding skills nor equipment.
I'd like to avoid the costs and the hassle of shipping the frame but I can drive within a few hours of NYC to get this done right: it needs to be able to carry 40-50lbs loads.
I finished the trip by immobilizing the eyelet with two fat zip-ties: