Hi there, I'm after some help with rust holes in a steel road bike frame. The frame is an unknown make but light weight. I had it sandblasted and it came back with tiny holes in the downtube.



I've read other material about how to deal with rust holes in tubes, but want to know more. I'm hoping answers provided could make this a useful sticky for dealing with this issue. I'd like clarification on my existing knowledge and assumptions about stripping steel frames and repairing rust holes. Having a clear approach to dealing with stripping and repairing for refinishing would be of great help to everyone who wants to restore bicycles. Your input is much appreciated!

Sandblasting or other media blasting, or chemical stripping? I made a conscious decision to have the frame sandblasted as opposed to the use of chemicals or other blasting media. The sandblaster I used explained he has experience with all types of frames and that it's the best way a) to make new primer stick and b) actually identify any issues with the frame (such as rust holes) that would be hidden by other/weaker stripping methods. This is contrary to comments that sandblasting as an abrasive stripping process is too harsh on thin steel.

Whether the tube should be repaired or replaced? I recently had another frame that had a cracked top tube that was obviously a candidate for replacement. But what about rust holes? What size or number of holes determines whether it needs to be replaced? Other threads I have read generally indicate it's ok to patch the hole, but does this maintain the strength of the tube? As far as repair options, I'm familiar with welding processes, and the sandblaster suggested drilling the holes and silver or bronze welding them, and I have also seen this approach mentioned in the forums. What about fibres and resins like fibreglass or carbon fibre repair? Can a thin sheet of fibre be applied over the holes or somehow inserted into the tube as a backing and epoxied? Can this approach maintain a strong tube? What can be done at home as opposed to seeking professional repairs?


Thanks
Andrew