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Attempt at aluminum head tube crack repair.

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Attempt at aluminum head tube crack repair.

Old 05-18-16, 04:22 AM
  #51  
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Originally Posted by 3alarmer
+1
this is a must for real strength
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Old 05-18-16, 04:26 AM
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I would have looked at having it TIG welded.
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Old 05-18-16, 08:19 AM
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Originally Posted by tgolden
you've set yourself up for a sudden catastrophic head tube failure.
.
Isn't this where you tell me the fork will come out and I'll fall and impale myself on it and die a slow agonizing death?

Bike is nice but only cost me 125$, it was worth doing a hail mary fix. I'm riding it about 20mi/day for the forseeable future. I keep my roll of duct tape with me if i get imapled I'll fix my self with the duct tape. Don't laugh, duct tape is a great first aid kit all by itself.
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Old 05-18-16, 08:31 AM
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Now that's a bike you don't mind putting a lot of money into...
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Old 05-18-16, 08:43 AM
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This frame is worth less than $100

My life is worth more than $100

I would just have bought a new frame. I also could never ride a bike this ugly.
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Old 05-18-16, 09:20 AM
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Originally Posted by eastbay71
This frame is worth less than $100

My life is worth more than $100

I would just have bought a new frame. I also could never ride a bike this ugly.
I never realized the cosmetic issue would be a deal breaker. here's a pic with tube covered with electrical tape. I put 2 frog lights on it and i have more on order. I'll probably put a red, white and blue one on it and make them flash randomly an make out like I'm a cop. Cars will get out of my way then.

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Old 05-18-16, 10:14 AM
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Originally Posted by kennj123
I never realized the cosmetic issue would be a deal breaker. here's a pic with tube covered with electrical tape. I put 2 frog lights on it and i have more on order. I'll probably put a red, white and blue one on it and make them flash randomly an make out like I'm a cop. Cars will get out of my way then.

or a cop will pull you over for impersonation
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Old 05-18-16, 10:26 AM
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Originally Posted by squirtdad
or a cop will pull you over for impersonation
hey, i just have a red, white and blue blinker on my bike. I'm trying to be safe and patriotic. whats wrong with that.
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Old 05-18-16, 10:26 AM
  #59  
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Illegal to have blue lights if not a police vehicle. Illegal to have red lights on the front, unless police. The chances of being pulled over are probably not too high. The chances of drivers thinking you're a police bike are even lower . . .
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Old 05-18-16, 10:32 AM
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Maybe you can list it on Craigslist for $300.
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Old 05-18-16, 11:14 AM
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Originally Posted by MRT2
Maybe you can list it on Craigslist for $300.
Frog 2X Silicone Bike Bicycle Cycling Head Front Rear Wheel LED Flash Light Lamp | eBay

I ordered some more of these frog lights. once I trick it out with some of them it will be worth at least 300$.
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Old 05-18-16, 11:36 AM
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Originally Posted by kennj123
I looked for Kevlar thread or any other kind at the boat shop where I get my epoxy supplies and they didn't have anything, just mat. I never bothered with kevlar mat because you need special scissors to cut it and their are other hassles. But the thread is interesting. Quite a few places are selling it on Ebay. Will any of the stranded versions work? It looks like they have a monofiliment for fishing. Weight test is only 60lbs, but it could be a lot thinner that the alternatives at the same strength.
You would want something with very low stretch such as Kevlar thread and do not worry about the tensile strength per fiber, that is where the 100 or more wraps come in. Presoaking the fiber in epoxy would ensure better penetration. I'd still either weld it or scrap it though...
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Old 05-18-16, 11:39 AM
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By now I am certain the OP fits the definition of TROLL.

Time to stop feeding him.

-SP
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Old 05-18-16, 11:41 AM
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Originally Posted by Homebrew01
Nothing terrible will happen. When the cracks get bigger, the headset cups will get loose, and the wiggling fork will let you know the party's over.
That is what I thought. To lose the front end of the bike, one would need some HUGE cracks, and several of them.

It might depend on the use of the bike. Commuter with a few potholes?

Heavy offroad MTB riding on technical rides along cliff faces?
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Old 05-18-16, 11:47 AM
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Originally Posted by kennj123
emailed seller and he said too bad.
This is why God invented baseball bats...
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Old 05-18-16, 11:56 AM
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The fix is useless. The forces that caused the crack are much higher than what can be constrained with your epoxy and randomly wrapped wire. However, the re-failure will probably be no worse than the headset going loose. I will be surprised if you get a month of riding before it starts to go again.
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Old 05-18-16, 11:59 AM
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Originally Posted by rmfnla
This is why God invented baseball bats...
He was pretty smart about it. He said the crack was so small he would never had seen it given his eyes aren't so good anymore.... Partly I didn't really have a great position, if the crack was there when i bought it I should have seen it, if it started after I rode it maybe its my fault, although their could be an underlying problem(corrosion) like other on this thread have said. I played it pretty cool though and said I was disappointed with purchase and told him about the crack. Mostly i was just fishing to see if he offered anything to makeup.

I grew up on a farm and their is a rule that when you buy cattle you can return to sender up to 30 days after purchase, even if animal dies. Amish won't honor anything like that when dealing with non amish. When buying from them only buy what you can see, like lumber and other things. Come to think of it maybe they just consider 'acts of god' to be on purpose so if the cow dies when you buy it its gods way of punishing you. I'll have to ask my brother, he still farms and has a lot of amish around.
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Old 05-18-16, 12:07 PM
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Unless you abused the bike those cracks didn't just appear.

Not sure about the second paragraph; was the seller Amish..?
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Old 05-18-16, 12:35 PM
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Originally Posted by jyl
Illegal to have blue lights if not a police vehicle. Illegal to have red lights on the front, unless police. The chances of being pulled over are probably not too high. The chances of drivers thinking you're a police bike are even lower . . .
In Canada blue lights indicates snow removal... and Blue Light is also the name of a watery beer.
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Old 05-18-16, 12:59 PM
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Originally Posted by kennj123
Hence the reason i put the stranded wire on there two. steel has 3x the tensile property of aluminum.
But stranded steel wire is elastic. It stretches. More than an aluminum headtube can stretch without cracking.

Further, you've wrapped the wire over fiberglass mat, which has little strength in compression (any strength it has comes from the epoxy). And instead of tight short wraps around just the cracked part of the headtube, you've wrapped a loose long spiral all up and down the headtube.

A force that tries to expand the bottom of the head tube will try to:
- stretch the couple feet of wire wrapped around the tube
- compress the mat/epoxy under the wire
- stretch the thin layer of epoxy covering the tube
- shear the bonded connection between epoxy and wire

All of those things only need to add up to a pretty tiny sum (couple tenths of mm) to make your repair ineffective.

It doesn't really matter because if the crack grows, the bike won't suddenly break apart, the headset will just get loose and the fork sloppy. But I hope you wouldn't try to use this sort of "repair" on anything that actually was a critical safety issue.
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Old 05-18-16, 01:50 PM
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The epoxy/wire "repair" is totally ineffective and is actually only a cosmetic fix, although in the wrong direction on the cosmetic scale.

You've done nothing effective to arrest the crack propagation or stabilize the failure. The crack will continue to grow and as evidence, you should be able to feel vibration and hear some noise as the effects of the propagating head tube crack become more apparent.

Do some internet research on crack repair in metal tubes under load or fixing anything metal with a crack under stress.
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Old 05-18-16, 01:53 PM
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Full face Helmet at all times .
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Old 05-18-16, 02:03 PM
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Originally Posted by tgolden
The epoxy/wire "repair" is totally ineffective and is actually only a cosmetic fix, although in the wrong direction on the cosmetic scale.

You've done nothing effective to arrest the crack propagation or stabilize the failure. The crack will continue to grow and as evidence, you should be able to feel vibration and hear some noise as the effects of the propagating head tube crack become more apparent.

Do some internet research on crack repair in metal tubes under load or fixing anything metal with a crack under stress.
Just came back from a 20mi ride on the death trap. I survived.
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Old 05-18-16, 02:13 PM
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Originally Posted by kennj123
I survived.
As you likely will for some time! Please post regularly up to and after your fatal accident.
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Old 05-18-16, 02:20 PM
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wtf.

srsly.
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