Madone Failure
03-04-10 | 11:04 PM
#1
Thread Starter
Making a kilometer blurry
Joined: May 2006
Posts: 26,170
Likes: 93
From: Austin (near TX)
Bikes: rkwaki's porn collection
Madone Failure
Ok, I took it apart tonight (pulling parts for my Fuji build).
Background story for the imaginary BFer who hasn't heard it: my 4-year-old Madone died when the BB shell came loose inside the frame. A repair attempt was made, but it didn't hold.
Tonight I mangled the BB shell out of it with a couple pairs of pliers and a pipe wrench. I managed not to damage the frame any more than it already was.
First of all, no freaking wonder it died. The amount of carbon supporting the BB is very small. It's like a 1/8" ring around each side of the shell. I've had 1750W sprints on this bike, and several 1' tests over 800W. I don't see how that structure could be expected to withstand full-time training like that. You get just a little give out of it in a pedal stroke, fracture the epoxy holding the shell in there, then every other stroke that flexes the frame around the shell is going to break off more and more of the epoxy bond.
Second of all, I think it can be repaired by someone who knows what they're doing. I'd think that if another wrap of carbon was placed inside the contact surfaces, that should tighten things up enough for a re-bond to hold.
When I had it repaired, we decided to save the BB shell for fear of not having a correct O.D. replacement available. I just don't think he was able to get epoxy in all the places that needed it.
Anyway, the pics show how frail everything looks. I don't see any fractures in the frame carbon.
Background story for the imaginary BFer who hasn't heard it: my 4-year-old Madone died when the BB shell came loose inside the frame. A repair attempt was made, but it didn't hold.
Tonight I mangled the BB shell out of it with a couple pairs of pliers and a pipe wrench. I managed not to damage the frame any more than it already was.
First of all, no freaking wonder it died. The amount of carbon supporting the BB is very small. It's like a 1/8" ring around each side of the shell. I've had 1750W sprints on this bike, and several 1' tests over 800W. I don't see how that structure could be expected to withstand full-time training like that. You get just a little give out of it in a pedal stroke, fracture the epoxy holding the shell in there, then every other stroke that flexes the frame around the shell is going to break off more and more of the epoxy bond.
Second of all, I think it can be repaired by someone who knows what they're doing. I'd think that if another wrap of carbon was placed inside the contact surfaces, that should tighten things up enough for a re-bond to hold.
When I had it repaired, we decided to save the BB shell for fear of not having a correct O.D. replacement available. I just don't think he was able to get epoxy in all the places that needed it.
Anyway, the pics show how frail everything looks. I don't see any fractures in the frame carbon.
03-04-10 | 11:19 PM
#4
Senior Member
Joined: Jul 2005
Posts: 1,341
Likes: 1
From: Orange Park, FL
Bikes: Ever changing..as of 2-24-09: 2003 Giant TCR Team Once, Sampson titanium, 1992 Paramount Series 3, 2003 Cervelo P3, 70s Raleigh Record fixed gear, 70s Fuji SL-12 commuter, mid 90s Klein MTB. Plus two or three frames lurking, plus 5 wife/kids rides
Did you measure the OD of the original? Nova has them in 6061 and 7005 alloys:
https://www.cycle-frames.com/bicycle-...-THREADED.html
https://www.cycle-frames.com/bicycle-...-THREADED.html
:
03-05-10 | 12:29 AM
#11
meow
Joined: Jan 2008
Posts: 5,831
Likes: 3
From: Hint: check out my BF name
Bikes: 2016 Parlee Altum, 2013 Cannondale Super Six Evo Hi Mod Di2 only, 2011 Cannondale Super Six, Dura Ace 7800, 2007 Cannondale System Six Dura Ace 7800, 1992 Bridgestone RB-1, MB-2, MB-3, MB-5
I'm awake, looking around and I bumped into this.
03-05-10 | 02:37 AM
#18
Primate
Joined: Jan 2006
Posts: 2,579
Likes: 5
From: gone
Bikes: Concorde Columbus SL, Rocky Mountain Edge, Sparta stadfiets
03-05-10 | 02:59 AM
#19
Has coddling tendencies.
Joined: Jul 2005
Posts: 8,360
Likes: 59
From: Topanga Canyon
Bikes: 2008 Blue RC8 w/ '09 Rival
I could fix that frame. JB Weld would definitely take part, as would a sheet of CF cloth. The following picture showing a possible crack through the bearing support diameter bothers me most. If that is cracked, then nothing can be done except use the frame as trolling fodder for the foreseeable future.
03-05-10 | 03:18 AM
#20
Primate
Joined: Jan 2006
Posts: 2,579
Likes: 5
From: gone
Bikes: Concorde Columbus SL, Rocky Mountain Edge, Sparta stadfiets
03-05-10 | 03:41 AM
#21
Has coddling tendencies.
Joined: Jul 2005
Posts: 8,360
Likes: 59
From: Topanga Canyon
Bikes: 2008 Blue RC8 w/ '09 Rival
03-05-10 | 06:32 AM
#25
meow
Joined: Jan 2008
Posts: 5,831
Likes: 3
From: Hint: check out my BF name
Bikes: 2016 Parlee Altum, 2013 Cannondale Super Six Evo Hi Mod Di2 only, 2011 Cannondale Super Six, Dura Ace 7800, 2007 Cannondale System Six Dura Ace 7800, 1992 Bridgestone RB-1, MB-2, MB-3, MB-5
I've never had a problem with my Trek other than never placing. Fork over $7000 for another Madone and stop being so cheap. Nice pics btw.