Got my '90 Trek bonded aluminum frame back from the sandblaster today and I think it looks pretty good. First time I've done this and I do have some work to do, but for $30, I'm happy.

edit: Just weighed the frame and it's 3.71 lbs!?

Keep the pictures coming as this progresses. Bonded Aluminum Treks are excellent bikes in my opinion.


Trek did a great job with getting a nice fit between the aluminum tubes and the "lugs". The lugs extend inside the tubes and strengthen the junction. That would be all good but it has to ride nice and I liked the Trek 1000 that I had for a short time.

$30 is a very decent price for sandblasting the whole frame. Did you have to clean sand out of all the crevices?

@JohnDThompson, who worked at Trek during the time these frames were being developed and rolled out, said that Trek had to use a flexible paint to accommodate slight movement in the joints to prevent cracking the paint.

I would think a 2k automotive primer, paint and clear coat might be flexible enough. While I have some knowledge, I'm not an expert.

I did stuff the BB, head & seat tube, but some media still got in, nothing that wasn't easy to blow & vacuum out.

My plan is to polish it, but we'll see how much of a PITA that turns into. With the finish being slighty rough, it would really give the paint something to stick to if I change my mind.

This is a Winter project, but got started on it anyway. Mainly using a palm sander (120 - 240 - 400 - 800) then a little hand sanding with 1000 - 2000 if needed. Frustrating part is it looks "perfct" but when I polish it, some of the sandblasting pits become noticeable and then I gotta sand it again.

Did your "guy" use sand? My powder coater/media blaster guy used walnut shells on aluminum frames.

I asked before I dropped it off and he said they use aluminum oxide.