The Merlin returns..
 

I have a 91 Merlin Road that I have trained and raced on for 15 years. In early august, I suddenly noticed lots of flex and unexpected gear shifts when jumping out of the saddle. On close inspection, I noticed that the downtube had a crack in it. The crack had propagated about 2/3 of the the way around the tube.
downtube crack
I contacted Merlin and because I still had the original receipt they said it would be covered under warranty.
Unfortunately they said it would take 5 to 6 weeks to fix. Because the bike was 15 years old, and had the original proprietary BB system and downtube shifter bosses, and I just couldn't go that long without a bike, I asked if they could just cut me a deal on a new CR 3/2.5 instead. The said they would give me a discount on a new CR /2.5 AND fix my old frame too! So within a week I had a new CR 3/2.5 to build up. Here is what I ended up with:
Merlin CR 3/2.5
Well, I was expecting to get my old road frame back and see what I could sell it for. I got it back after about 6 weeks and I couldn't believe my eyes. The frame looked like brand new! The factory had replaced the downtube, replaced the bottom bracket shell, put new shift cable stops on the head tube, and refinished and re-stickered the entire bike. The only indication that is was not a new bike was the old style rear dropouts with the original serial number stamp on it.
91 Merlin Road reborn!
bottom bracket shell
head tube
Many thanks to the people at Merlin.
They really know what customer support is, and they really know how to make fine Ti bikes!
You really can't own too many Ti bikes can you?

those sure are purdy welds.

Sweet bikes!

If you're at the front, who's taking the picture?:D
http://home.comcast.net/~strombad/moab_mud.jpg

I usually don't let my nose hit the wind, but got lucky considering the backdrop.

Fantastic story and great outcome. I cannot believe how good the older Merlin looks after repair. Kudos to the staff at Merlin...

Lucky!

Nice result, Strong Bad. It appears you've equipped both bikes with DA and the same sticker-less wheels (appear to be Reynolds Alta Race), or you moved the gear from one frame to the other for the pictures - so which is it? Either way, great bikes and a great service story. :)

They are both equipped with DA and Alta Race. The only thing I'm swapping right now is the seat bag and pedals. (Still waiting on a backordered set of X/1's).

Awesome! :beer:

God I love titanium! :D

the same thing happened to a friend...the crack was at the same place. I think the downtube is thin there and the welds for the shifter bosses weaken the tubes just enough that they crack about 12 to 15 years down the line.

I think you're right. The crack looked like it had started right at the weld of the right shift boss. Also, the downtube is probably the most highly stessed tube on a bike. I'm glad I have the head tube shift cable stops now.

This is the reason I want a Merlin. Top notch bikes built by top notch guys.

Both good looking bikes, glad to hear that they treated you so well.

That's called good customer service - glad to know it still exists!

Wow, awesome customer service!

As a Merlin owner I am glad to hear this story (even though a used one in the early 1990's)

Super cool, outstanding service and customer satisfaction