Thanks for the thoughts guy! I been thinking about these things too. I discount any safety concerns mostly because I'm on the lookout.

The cost of the components is substantial but not excessive. I'll have built a 10-speed double bike for less than $500 that will be light and durable(?). About what a xBox One cost when you had to get it with the Kinect. I'm going to build the wheels (a first).

I want to continue to look into solutions in part because I am concerned what my son will think of it with a hose tie. It isn't a stigma to him because he knows his dad saves stuff from the scrap heap and he's already been the beneficiary of my finds. He also knows that we need to save money for other things. He's seen it and hasn't been repulsed. But it IS a hose clamp.

I could have a lathe but I wouldn't know how to use it. Are you interested in a project? (JK)

These cracks come up from time to time in BF discussions. It's a flaw but there's no suggestion, that I've read, that it leads to a rapid failure. Handling issues, if any, will be sorted out long before he rides it.

There's no recourse through Spesh. I bought it second-hand and that means there's no warranty. No biggie.

Fit and a different frame... How do you fit a moving target? Haha He grew six inches in two years and is on track to continue that pace this year. At 5' 6-1/2" today, he'll be 5' 8" in the fall. If the bike is too big this early summer, it may start to feel right in the fall and by next year it will be a fit. I'll have to slam every I could see building this around a 54cm frame but the cost would have to be right, darn near free would be about right.

I'll keep googling for a more durable/aesthetic solution for reinforcement. The frame isn't riding off, scot-free, just yet.