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Cracked bottom bracket shell in Cannondale Synapse Hi-Mod 2015

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Cracked bottom bracket shell in Cannondale Synapse Hi-Mod 2015

Old 05-25-23, 05:13 AM
  #1  
.johnny
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Cracked bottom bracket shell in Cannondale Synapse Hi-Mod 2015

Hi folks,

after spending hours checking each and every bearing in de drive section for reasons a tick appeared on each pedal for a few rides after a thorough bike-clean, I finally came across my nemesis: a small crack in the bottom bracket shell of my Cannondale Synapse Hi-Mod 2015.
Here's what it looks like; note that the picture was upside down (bike was), so it is on the top of the shell. I've been searching for potential solutions or experiences with this problem, but haven't really seen anything similar enough anywhere, so am looking for advice how to treat this. I am not even sure what kinf of material the shell is. The frame is carbon, but I suppose the shell is alloy? Any tips / suggestions welcome!
- can't add images intill I have 10 posts so they will follow soon -
for reference, the part schematics from the manual:
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Old 05-25-23, 05:15 AM
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images, unlinked/displayed:
cimg5.ibsrv.net/gimg/bikeforums.net-vbulletin/722x811/image_2495b8fb8b11fe01a46f304f0954ee9de43fa841.png
cimg7.ibsrv.net/gimg/bikeforums.net-vbulletin/380x524/image_a6a887e367e0ddf554aa623de967e6d755905eda.png
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Old 05-25-23, 05:40 AM
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I am indeed not the original owner of this bike, not sure I can track that person down, so am indeed looking for economical solutions. I've seen sites about carbon repair being expensive, but also reckon this is largely due to getting the esthetics right and fitting it perfect, while in this case to my unexperienced eye, it seems there may be room te fix this pragmaticallly: there is a lot of room and it will be invisible when you install the cranks.
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Old 05-25-23, 07:06 AM
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Cracked aluminum. The obvious thing to do would be to stop-drill the crack, but I doubt even a 90 degree Dremel head would fit in there. So the next best approach would be to sand, clean and epoxy a few layers of fiberglass over the area to try and stabilize it.
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Old 05-25-23, 07:39 AM
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yeah, have been thinking about access; would have to check carefully, but there is a hole in the frame under the shell (see the link to second pic above), whith a plastic cable guide and cover that you can open and take out (would have to unwire to take it out).

However, the crack is on the other end of the shell (top of the shell, not the bottom). There are big holes in the shell, so if I'm lucky (doubt it, given this much bad luck) perhaps it is possible to reach through that hole for the cables and holes in the shell itself to meet the crack orthoganally with a drill.
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Old 05-25-23, 07:44 AM
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Originally Posted by shelbyfv
You can put the pics in your Album.
Those pics are already there, I'm just not allowed yet to link to them here yet, hence the url is posted in the second post with https in front.
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Old 05-25-23, 08:00 AM
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Image assist
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Old 05-25-23, 08:10 AM
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Good old Crackandfail strikes again.
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Old 05-25-23, 05:28 PM
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Original owner, or not.. contact cannondale and see if they will help out.... hey, it's worth a try. It may be a known issue and it's better for them to handle it than ignore it.

If i were them, i'd offer an update, new frame at cost,, or ever free...

Last edited by maddog34; 05-25-23 at 05:31 PM.
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Old 05-26-23, 07:13 AM
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Originally Posted by maddog34
Original owner, or not.. contact cannondale and see if they will help out.... hey, it's worth a try. It may be a known issue and it's better for them to handle it than ignore it.
Thanks. Would you contact them directly, or should I go through a dealer? sorry - new to this.
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Old 05-26-23, 12:08 PM
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Originally Posted by .johnny
Thanks. Would you contact them directly, or should I go through a dealer? sorry - new to this.
dealer first, then escalate to direct contact if the dealer dead-ends it., but be polite.... having worked in retail,counter folks mentally shut down when insulted or yelled at... it's a coping tool.... usually thankless work.

a customer showed appreciation once for a rapidly handled repair to his expensive construction equipment by bringing us all a gift card to a local upscale restaurant... guess who's stuff got fixed first from then on? $25 bought almost three of their bacon cheeseburger baskets back then!
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Old 05-26-23, 12:19 PM
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Originally Posted by .johnny
Thanks. Would you contact them directly, or should I go through a dealer? sorry - new to this.
I would go direct. The dealer didnt make the bike and the dealer warranty is probably up. The manufacturer should warranty their own product.

it just came to light in the sneaker community that dealer warranty and manufacture warranty are not the same. We found out that nike will warranty shows up to two years old. The dealer aka store 30-90 days.

and instead of trying your best to be nice and keep composure try asking chat gpt to right you a great email explaining your situation wtvr else you want to include. Then send it

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Old 05-29-23, 07:30 AM
  #13  
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Originally Posted by Kontact
...I doubt even a 90 degree Dremel head would fit in there.
Are you on friendly terms with any dentists?

This would fit into a BB shell. Low torque, but high speed (~300,000 RPM).
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Old 05-29-23, 08:04 AM
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I don't think you have any chance w/o stop drilling that crack. I would try a local machine shop or two. I have seen amazing work in shops
and odd tooling like 12" long 1/16" drill bits.
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Old 05-29-23, 09:33 AM
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Cdale has limited lifetime warranty. and are usually very good with their coverage. Must go through an authorized dealer, not direct. The dealer relationship with Cdale is critical as they will do more for dealers that are on good terms with them. Only original purchaser has the warranty, it is not transferable. If the frame has been registered with Cdale by the dealer or original owner, you may not be able to make a claim.
With all that said, it don't hurt to try!
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