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Source for Cannondale shifter boss assembly

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Source for Cannondale shifter boss assembly

Old 08-30-18, 10:53 AM
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Source for Cannondale shifter boss assembly

I’m looking at a vintage Cannondale for my girlfriend. Nice, vintage small sized frame could be fitted nicely to her. Problem is, there are 2 holes in the downtube aluminum tube where the shifter bosses are supposed to be. I’ve seen the correct ones occasionally on eBay, the ones with the right size concave washers and the square posts to accept downtube lever or STI adjuster barrel stops. Unfortunately, a quick check today and I was unable to locate any.
I’ll probably check with my local Cannondale dealer but fear that the item I am seeking will be like looking for a white unicorn.
Any help that vintage Cannondale folks could provide would be great! I would love to hook her up with some awesome made in USA 1980’s tech.

Last edited by masi61; 08-30-18 at 01:33 PM.
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Old 08-30-18, 11:34 AM
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I don't know if any of the originals are available anywhere but I had to replace a similar downtube boss arrangement on a late-'90's Trek-made "Klein". I couldn't get the originals either so I did the following. Note: This fix only works for fitting Shimano-type STI downtube cable stops, not actual shifter bosses.

A pair of Shimano downtube cable stops. Preferably the flat back style for your large diameter downtube.
4" or so 10-32 bolt and nut.
A 3/16" drill bit.

Enlarge the existing holes in the downtube with the 3/16" bit. Work carefully so as not to leave burrs.
Drill out the M5x0.8 bolt holes in the downtube stops to 3/16" also
Thread the #10 bolt through one of the downtube stops, then through both sides of the downtube and then out through the other downtube stop. Keep the left and right side stops in the proper order.
Thread a #10 nut over the protruding end of the bolt and tighten it firmly against the downtube stop. Blue Loctite on the threads is a good idea.
Cut off any extra bolt length flush with the nut and file it smooth.

That will give you cable stops that will never come off and are far more secure than the factory ones.
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Old 08-30-18, 11:40 AM
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NOVA and McMaster-Carr, I think, both sell a setup that can be made to work. You'll have to sand down the bosses to fit the larger downtibe diameter, but that's no big deal.
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Old 04-22-19, 08:19 PM
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This ebay seller has then

Found some on ebay search for "ebay.com/itm/Vintage-Bicycle-Down-Tube-Shifter-Levers-Bosses-Bolt-On-Bike-Tube-Bosses.

I have a 1994 Cannondale R 400. This is my first bike and I wanted to join the MS bike fundraising event with this bike. Now the boss is broken for the shifters. If someone has the same part for a 44.5mm tube within USA, please let me know.
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