Says the master that preserves the chrome on the fork crown when replacing the steer tube!!!

I'm seeing notes that a powder coat may endure a second baking cycle. So, you may be able to only refinish the damaged portion.

It would be cool if you could do contrasting colors like the old Motobecane bikes, but it would probably be complex to get it to turn out very nice.

You’re handling this very well, considering the circumstance.

FWIW, another bike with a bulging head tube came up here a couple of years ago (link).

[MENTION=381793]gugie[/MENTION] - is that one of the frames you picked up at the Seattle Bike Swap a couple months ago? I guess I'm glad you picked it before I got to it :(

Is there a bulge on the bottom side of the top tube? How about just above the down tube, within the headtube, is there a slight bulge there too? Where was the seam in the headtube (if it had one), assuming you saw the frame sanded down before it was powder coated? I'm trying to understanding how a compressive load would create a bulge like that, in that location... I have this theory that the headtube was overheated during the brazing process, severely weakening it, and it hasn't shown up until you attempted to compress in the headset (it's just a theory).

Crap indeed.

I cracked a head tube once with a headset install, but that was aluminum. Maybe it can be saved for use as short distance pub bike/grocery getter

I was thinking:

https://www.bikeforums.net/classic-v...-aww-crap.html

Naw, this is the one.

https://c1.staticflickr.com/1/886/40...07e0cd98_b.jpg

Yeah, and I promise I won't tell anyone.

interesting failure. The top tube bulge I would have expected on the upper side of the tube, as the headset press has overpowered the head tube and compressed it. note though that the materials and processing was done along time ago in a known rushed time and may have been a booby trap lying in wait for you. Does make one think about checking the head tube ID and comparing it to the actual selected headset OD.
Campagnolo for their tools and headsets has a Passa/No Passa dimensional gauge. They held the OD of their headset parts in very close intolerance.

Thinking, a headset reaming and facing tool as it wears from use will bore a smaller diameter hole. I would check that for reference.
Once burned... I have purchased a new cutter for my Campagnolo tool.

Looks like a massive over-heat during braze. I have seen it break down dead soft when the temps go to the moon.

The steel just doesn't stand a chance. Its a fundamental change.

Just an idea.

Yeah, but this ain't a real old tool, and I keep good care of it. If it were that undersized I would have really had to wrench on it to press it in.

I'd bet that you guys are right.

Man, that's gutting. Really sorry. :(

A mechanic at Bike Works would classify that under the Peanut Butter Jar Effect. From creation to this moment, that frame's history is largely a mystery and who knows what quality issues, riding, and component installation--prior to your stewardship--it endured (that weakened it). Enough people try and fail to open the peanut butter jar, and then the last person is able to, and usually without too much hassle. Dagnabbit.

Be encouraged that this is an outlier. Like you've said, plenty sloppily-assembled Raleighs and other bikes have not failed (nor failed under your care), so this is a fluke, albeit a really pretty-looking one.

Know that my '74 Paramount and '82 Miyata 1000 are still kicking butt and that I continue to have full confidence in them. You gave both of them a new lease on life and they continue to set the bar for top-flight ride quality in my fleet, something which I really appreciate. The Paramount can also properly hustle when called upon. That's a lot of fun!

That is devastating. Between your GS and [MENTION=479372]lacro[/MENTION] Super Course it hasnt been a good week for Raleighs on the forum.

Yikes! Condolences.
Up to that point what a Beauty.

I'm rather with Ghrumphy, it should be possible to salvage it. The bulges are associated with the lug edges, so that's where the stress risers are. So I would first, suggest not to try to bend it back unless there's a pressing need.

Is the head tube significantly displaced from where it was? If so, the steering geometry might not be acceptable any more, but this is your judgement call. Measure the current head tube angle and compare to your previous measurements (if any), or at least also measure the seat tube to see if they are still close to parallel. I don't expect it has been displaced significantly. Measure the fork offset and compute the trail you'd expect to get. If that's ok, you can salvage this into a decent bike ...

... If you can make the top and bottom of the head tube perpendicular to the tube and (by definition) parallel to each other. I'm not sure if your tool will let you mill the top face relative to the bottom face, and you'll have to decide which one to use as the reference for the other. Assuming the bottom face is undamaged and accurate, I'd imagine (I've never milled a head tube myself) you can level the top, at least with lengthy and careful application of a hand file.

After that, if the bearing centers upper and lower are aligned, I'd think you can assemble it.

This makes my little paint issues not so bad, I've been over zealous with my repaint.

Given your skills, excellent projects and classy stable I don’t feel bad for you at all [MENTION=381793]gugie[/MENTION]. Plus I'm pretty sure you make good soup. So have a beer and a laugh and when you’re ready turn it into a rider of some sort. If you do that I’ll bet you’ll either come to appreciate it as is or find someone else who will.

Things like this are gut wrenching to me also, so, you have my sympathy. But, if there is a silver lining to this, better that you find out about the possibly weakened headtube prior to you ever riding the frame and sustaining a head on crash. A crash like that is scary enough, but with collapsing headtube... if might end up much worse for the rider. I know that's not much to hang a hat on...

A blow to the pride to be sure but I've ridden much worse than this. Don't worry about it.

There are always setbacks and some thngs you can't control. Or you learn and experience is everything.

I fancy myself (lol) as a solid rider, not saying speed wise necessarily. But handling of different types of bikes and ride fairly aggressive at times. To me that part of riding is like skating. You have to fall to get better, and know how to fall to not get hurt.

Well, a couple weeks ago I saw an older friend. He was riding with the Slow Spokes group that is local to me as I live near a retirement community. Of course....I was the one who did not get unclipped at a light and tipped over. I could splain myself but does it really matter. Hahaha. It's all you can do, then hop back in the saddle.

I think you should send it back to Raleigh for a warranty replacement.

Yep, I had the frame media blasted before brazing new bits on, and inspected all of the lugs prior to starting.

I was expecting that reply.

UPDATE!

Tonite, with a lot of encouragement, I pulled the headset, re-faced the upper lug, and pressed the bits back together, carefully. After reinstalling the headset, it spins perfectly.

I'm gonna ride this frame.