Well, first, the stud in the original design failed, so perhaps that's one vote for a new fork. But if the stud is indeed threaded and easily removed, I see no magic in replacing the stud. Heck, the replacement stud might even be stronger than the original.

But if you have to get into drilling and tapping and you aren't familiar with machine shop work, buy a new fork. If you have to get a new stud welded on (and would have to strip and repaint the original fork), buy a new fork.

But the fact that stud repair kits are sold tells me that a replacement stud may be more reliable than the original. They're brakes, for sure, but everything on a bike should be repairable or replaceable in some way.

Studs are threaded and easily removed on aluminum bikes. This is steel and its brazed on. There may be exceptions in the world, but I've never seen a steel fork with threaded-in brake studs that can be easily replaced.

Any solution that contains words like "drilling" or "tapping" are a hack and should be off the table.

I realize money is tighter for some people than others, but we are still talking about only $80 here for a new, safe, properly installed fork. Total cost of his Trek 730 is going to come in at only $220 and he ends up with a very nice bike that most of us would call a "keeper".

I defer to your expertise regarding brazed vs threaded construction on steel and al respectively. But respectfully drilling and tapping are only hacks if you don't have the expertise and experience to do it properly. I have a modest amount of expertise and would be comfortable doing it. A real machinist could do something like this in his/her sleep. But for someone without the expertise, who does not have a milling machine handy and experience in odd-shape workholding, I concur.

Hello all, I have fixed the fork and just went with it. The chrome doesn't look too bad and now she runs very well. :) Thanks all for your help!


http://i.imgur.com/HbdV5cg.jpg

Sweet! Now that you have a chrome fork, you've got the "bling" started. Start by replacing those ratty old plastic toe clips with some nice chrome steel ones. :)

But seriously, I'm glad it worked out. And for less than the price of a cheap Walmart bike, you ended up with a very fine machine that will serve you well for as long as you want it to. You might want to upgrade later in life, but you really don't ever "need" to. Congratulations.

Very nice indeed.

Forgot to mention. Most people replace those adjustable stems. They almost always loosen up and even when they're good and tight, they tend not to feel as "secure" as a solid stem. The way to use the stem you have is to adjust it to your liking (that might take a while to dial it in just right), and then try to find a solid stem that puts the bars in the same place. Stems are dirt cheap.

What adjustable stems are you talking about?

Handlebar stem - the silver part that fits into top of the fork, that holds the handlebars. The height of your handlebars is adjustable (up and down) as with any normal stem, by loosening the bolt at the TOP of the stem. Stems like you have also have that joint at the bend, which allows you to adjust the angle/front-to-back position.

Once you figure out where you like the handlebars, buy a solid stem, without that joint in the middle that is going to loosen up and will always flex no matter how tight you make it. Not something you need, but you will feel a difference with a solid stem. It will feel more "secure" to you, especially if you start really pushing yourself and the bike.