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Making A Derailleur Hanger (Vitus 992)

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Making A Derailleur Hanger (Vitus 992)

Old 12-15-11, 09:22 PM
  #1  
jyl
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Making A Derailleur Hanger (Vitus 992)

Thought this might be interesting.

I bought a French frame with a missing dérailleur hanger. No-one, I mean no-one, sells the correct hanger. Not here, not in France.

One option was to find one that is "close" and modify it. Problem is, not just the shape but also the holes need to be close. That is hard.

Another option was to get some aluminium plate and cut a hanger by hand. You could do it with a jigsaw. But there would be tedious cleanup required, and then I'd just have one hanger. Suppose I broke it?

I decided to "do it right". I use a micrometer to measure the hanger, and figured out what could be simplified for easier fabrication. I ended up with a Google Sketchup file, which I converted to an AutoCAD DWG file. A local water jet shop cut ten pieces from 5/8" (edit: correction, should be 3/8") 6061 aluminium with the holes drilled where I specified.

Here is a picture. The parts are a hair oversize, so that with a bit of file work, they will fit precisely in the recess of the dropout. It is the same thickness as the recess. I still need to tap the derailleur mounting hole, and chamfer the mounting holes. Maybe polish, and round off the edges, so that it looks more like the original. But I've checked the fit and am 99% sure there will be no surprises.



So, if anyone has a Vitus 992 frame that is missing a derailleur hanger . . .

Last edited by jyl; 12-16-11 at 10:31 AM.
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Old 12-16-11, 07:40 AM
  #2  
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Nice work!
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Old 12-16-11, 07:44 AM
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I agree good job. now you can clean them up and start selling them. I do not know the size off the top of my head but the tap for the RD bolt is available at most any good hardware store that selles taps
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Old 12-16-11, 07:47 AM
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That looks real nice. I must be missing something, though. Did you say these are 5/8 thick?
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Old 12-16-11, 09:00 AM
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I have a bent 992 frame, looks like you wont need the hanger but if you do I should have one (cant find a photo and the frames in strorage)
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Old 12-16-11, 10:10 AM
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Originally Posted by rootboy View Post
That looks real nice. I must be missing something, though. Did you say these are 5/8 thick?
He said they were made from 5/8" thick stock.
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Old 12-16-11, 10:26 AM
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Originally Posted by Bianchigirll View Post
I agree good job. now you can clean them up and start selling them. I do not know the size off the top of my head but the tap for the RD bolt is available at most any good hardware store that selles taps
I've found that the hardware store usually only carries the more common M10 X1.5 taps, not the M10X1.0 that most deraillers require. I had to order mine as well as a bolt as an aligning tool from Fastenal.

Really great job on those hangers.
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Old 12-16-11, 10:30 AM
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The original hanger is 7 mm thick at the quick release and 9 mm thick at the rear derailleur mounting hole. Campy specs say anything from 7 mm to 9 mm is okay at the RD hole. For ease of mfg I told the shop to use 3/8", which is close to 9 mm. (Sorry about the typo where I said 5/8" above, good catch!). I haven't measured the piece to verify that they did, but it appears to fit perfectly.
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Old 12-16-11, 10:47 AM
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I need to go out and buy a drill press to chamfer the hanger mount holes, a tap to do the RD mount hole, possibly a bench top grinder/buffer to polish and round off the edges. Not the cheapest project in the end.

I bought the frame cheap because the seller couldn't find a replacement hanger after shifting his RD into the spokes on his first ride after building the bike. "How hard can it be to replace a hanger" I thought . . . Very difficult, it turns out. I originally built a full 3D model to have a CNC machine shop reproduce the original part exactly, but the cost was going to be prohibitive. I realized the original part was merely cast and not terribly precise in dimensions anyway, so there wasn't much point in spending more money to precisely replicate some superfluous curves.

Water jet cutting is interesting. They can cut up to 5" of aluminium. I'm planning a kitchen remodel (when $20K shows up, like never . . .). Going to build the cabinetry myself, have a custom pot rack idea in mind, was thinking I'd need to hire a custom metal welding shop, now I think I can do it using water jet cutting.
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Old 12-16-11, 10:56 AM
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Cool part. You can do the chamfers with a countersink tool and a handheld drill.
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Old 12-16-11, 02:28 PM
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I just discovered that my aluminum Centurion Facet doesn't have a replaceable hanger. The hanger is an extension of the AL frame and if it so much as gets bent, I could be out an entire bike! This is a great solution.
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Old 12-16-11, 05:53 PM
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In that situation, it might make sense to have the bent hanger straightened, or the broken hanger welded back to the frame. A local welding shop could do it for not crazy money. I've never had that situation. Personally I might take it as an excuse to get a TIG welder . . . I didn't put 240v in the garage without a secret plan!
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Old 12-16-11, 05:56 PM
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Nice, engineering at its finest! If I had access to a shop I would love to make things like this.
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Old 12-16-11, 05:58 PM
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Originally Posted by Grand Bois View Post
He said they were made from 5/8" thick stock.
Yes, I know.
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Old 01-05-12, 05:00 PM
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I missed you by about 9 months-I had this exact same problem last March (see my thread). I bought a 992 that was missing the derailleur hanger, figuring I could probably find a replacement. No luck. I didn't even have a damaged original to work from, so I found someone in Scotland with the same bike & asked him to make a drawing of the part for me. Met someone with a benchtop CNC setup, and he cut it for me. Wasn't quite right, but I made it fit with a little file work. Working fine so far, although I haven't put a lot of miles on it (turns out the Vitus frame is a little small for me).
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Old 01-05-12, 05:45 PM
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Nice job, jyl.

Now that you've gone through this trouble, there's also the easy way out: http://www.ebay.com/itm/Vintage-Vitu...item56478d3afa
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Old 01-21-12, 10:35 AM
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do you still have these pieces?

I'm missing exactly that piece. Do you still have them? are they for sale?
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Old 01-21-12, 10:55 AM
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Originally Posted by gaucho777 View Post
Nice job, jyl.

Now that you've gone through this trouble, there's also the easy way out: http://www.ebay.com/itm/Vintage-Vitu...item56478d3afa
Not sure if that one in eBay will work for the 992.
That one is what was used on the Carbone 7 & 9 which I think had an entirely different rear traingle and DO design.

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Old 01-21-12, 10:30 PM
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The eBay seller of the Vitus rear dropout knows his stuff. I corresponded with him in the course of my search. However, he describes the part as fitting "all Vitus alloy frames" and my bike has carbon fiber stays. Anyway I didn't want to detach carbon stays from alloy dropout. I actually have no idea how to do that.

jeoen, I just got the tap and haven't had time to finish a hanger yet. If you are in a hurry for the part, you can contact the eBay seller who has a used original hanger for sale (at least he did a few weeks ago). Also prettyshady above has one, if I read his post correctly. If you don't get your hanger from them, I will have mine ready - err, within a couple weeks - and I'll be happy to sell one.

Just PM me, or post here and I'll see it and will PM you.

Last edited by jyl; 01-21-12 at 10:34 PM.
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Old 01-21-12, 11:31 PM
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Originally Posted by jyl View Post
The eBay seller of the Vitus rear dropout knows his stuff. I corresponded with him in the course of my search. However, he describes the part as fitting "all Vitus alloy frames" and my bike has carbon fiber stays. Anyway I didn't want to detach carbon stays from alloy dropout. I actually have no idea how to do that.

jeoen, I just got the tap and haven't had time to finish a hanger yet. If you are in a hurry for the part, you can contact the eBay seller who has a used original hanger for sale (at least he did a few weeks ago). Also prettyshady above has one, if I read his post correctly. If you don't get your hanger from them, I will have mine ready - err, within a couple weeks - and I'll be happy to sell one.

Just PM me, or post here and I'll see it and will PM you.
JYL: talk to Ruckus- http://www.ruckuscomponents.com/ . They'll know about debonding/bonding of carbon fiber and aluminum parts.

Back when I was working at Euro-Asia Imports, there were replacement dropouts and fork ends available for the 979 models. There were a couple shops that would do repairs on Vitus frames. I'm not sure there were replacements for 992 frames.

And since you're in Portland, I hope you knew that Terracycle machines a fair amount of parts for recumbent bike accessories. They have a couple CNC stations on site.
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Old 01-22-12, 01:21 AM
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Regarding the derailleur mounting threads, an alternative option is a T-nut, such as these: http://aebike.com/page.cfm?action=de...=30&SKU=TL4067 The benefit is that they'll be dead square, you don't have to worry about tapping the threads normal (in the geometric sense of "normal") to the plane of the frame.
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Old 01-22-12, 05:55 AM
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Very impressive! be sure to let us see the finished product.
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Old 01-22-12, 11:05 AM
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Thanks for pointing to the T nut. If I have trouble with the tapping, that will be useful. At $20, might make the completed part kinda expensive. I'm borrowing a drill press to do the tapping (turn by hand, motor off, but the press would keep everything normal aka orthogonal).
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Old 01-22-12, 12:01 PM
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Another possible approach to tapping would be to clamp a 10x1 nut to the hanger somehow, and use it to lead in the tap. I envision a couple pairs of Vise Grip pliers holding the two parts together, perhaps.
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Old 01-26-12, 02:00 PM
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hanger 922

I'm not in a hurry for the part, I'm trying to get the bike complete so I can sell it. The other solution of dismantling the frame to put the piece with the fixed hanger in doesn't appeal to me. Too risky.
If you could sell me a piece once you have them finished I would be very happy!
Please keep in touch.
J
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