vintapperen

I have a work colleague (not the original owner, so no warranty unfortunately) who has an early-ish Trek 5500 where the bottom bracket shell is becoming disbonded from the carbon frame (this would be the original type of bottom bracket shell, I think?). Now the question is - is there anything that would hinder us pressing out the aluminum BB shell so we can re-bond it? We have a full precision engineering workshop complete with precision engineer here at work and I have many years experience in the marine industry working with laminates and epoxy adhesives, so I think we can do the job, would just really appreciate some clarification on the BB construction. Also any other information that you think would be relevant would be great. Thanks!

Ex Pres 

Don't tell me you're the third one with this issue.
Two earlier threads in the Road forum have hashed this out.

vintapperen

Hi - could you post a link to these threads then. Thanks

zoodude

https://www.bikeforums.net/showthread...ight=trek+5500

https://www.bikeforums.net/showthread...ight=trek+5500

vintapperen

Thanks! - there is some useful information in there.

RacerOne

How in the world did you sort through all that and find any useful information? You've got the patience of a saint.

vintapperen

There was a lot of noise in that last thread! - about 3 useful posts out of 800+

Not sure about having the patience of a saint, but the owner of the frame is a good guy and I would like to try and help him out. Will post an update when we have done a repair.

mconlonx

If you're unsure about doing the repair yourself, Calfee bikes says they repair CF.

vintapperen

Late update:

Actually it was a pretty easy repair.
1. The aluminium insert is is just a straightwalled cylinder and using a BB tool and a long spanner we made sure it was tuning freely (i.e. we broke the glue bond completely).
2. By gradually screwing out one of the BB cups and using a press we pressed out the insert.
3. Cleaned all the old epoxy from the mating surfaces.
4. Using a lathe put a straight knurl on the insert for better 'grip'
5. Reglued the insert using a high-strength two-pack epoxy

It has been in daily use for several months now

lancem631

Really appreciate you posting a solution. Without scanning all the previous threads, did you determine this disbonding as a manufacturing defect, Trek design flaw, or just one of those edge case issues? I have a 2005 Trek Pilot 5.0 on the way to Ruckus Composites in Portland to be analyzed for the same thing. So far, Trek has denied any warranty claim and will not accept any responsibility. I am the original owner with the Trek Lifetime warranty.

Iride01 

Methods for dealing with these kind of BB issues has changed a lot in the 12 years since this post was made. You should really ask your own question in your own thread and get some more up to date info.

Welcome to BF.

lancem631

My question was directed to the OP. Unfortunately reference links are no longer valid also.

cxwrench

The last time he was on the forum was 9.16.2010. I don't think you'll be hearing from him.

biker128pedal

Did you have your receipt? They are picky about they. Still it is odd Trek did not offer to fix it. My 5.0 the rear drive side drop out broke. Trek was going to remove and Rebond a new dropout. But they found a crack in the top tube so offered an Emonda frame. I took the credit and got a Domane SL6.
But I did have the original receipt. A scanned copy was good for the Trek store to send in.

lancem631

Yes I still have my original invoice from local bike shop as proof of ownership. What year is your 5.0 assuming Pilot 5.0? How long ago was your claim? I had no offer to ship my frame to Trek for further inspection. I would certainly appreciate knowing details of getting your broken frame back in the hands of Trek. Did they offer to inspect or did you request?

biker128pedal

It was a Madone 5.0. 2007. I worked through the shop I bought it from that had converted to a Trek store. Still seems odd they would not make it right. Shop was Trek Williamsburg Virginia. Was a Bike Beat Williamsburg.