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Drilling holes in a steel frame?

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Drilling holes in a steel frame?

Old 03-13-22, 10:10 PM
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Polaris OBark
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Drilling holes in a steel frame?

I have two different steel frames I am considering drilling holes in, in order to run internal Di2 wires. However, I don't want to ruin them. Is it possible to drill a small hole to thread in a wire without compromising the integrity of my frame? Should I pay a framebuilder to do it right? Should I forget about the idea?

The two frames are a Soma Saga (touring bike) and an Advocate Seldom-Seen (an off-road steel bikepacking frame). Neither of these are extremely expensive, but I don't want to screw them up with some amateur-hour modifications.

If I do this, is there anything I can do to minimize the risk of screwing up?
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Old 03-14-22, 01:31 AM
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guy153
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Should be OK. The best place to drill them is probably about an inch and half from the joints so that you're still in the thicker part of the tube but outside the heat affected zone. Make them as small as possible and debur them carefully with e.g. a small file. You might actually even be better to use a slightly dull drill bit for a smoother hole.
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Old 03-14-22, 06:33 AM
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I will jump in here and ad my 2cents!
Took a frame building class 2 years ago and ran my dyno wiring inside the tubing. I used a reinforcement "washer" or bottle boss star reinforcement at each hole. These were silver brazed on. Just finished a mixte for my wife and did the same.
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Old 03-14-22, 02:39 PM
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Thanks to both of you for the replies. It also makes me realize I have the option of taking the cowardly way out by using currently existing bottle boss mount holes.
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