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.

http://img718.imageshack.us/img718/2401/dsc04497t.jpg
http://img29.imageshack.us/img29/4986/dsc04498r.jpg
http://img36.imageshack.us/img36/5742/dsc04499m.jpg
http://img402.imageshack.us/img402/7185/dsc04500m.jpg
http://img94.imageshack.us/img94/1340/dsc04501p.jpg

Truth unleashed.

Another reason why to never buy a Trek.

Did you measure the OD of the original? Nova has them in 6061 and 7005 alloys:

http://www.cycle-frames.com/bicycle-...-THREADED.html

What did you expect? The candy coated shell on that thing had been compromised.

http://www.partypaperlife.com/assets...s/PPL00345.jpg

What size is the frame?

Just out of curiousity, would you mind posting a pic of the other side for comparison?

6. He's been hoping to squeeze into a 4 before the prom.

This should be good
:popcorn:

Throw some over here!

I'm awake, looking around and I bumped into this.

Are Treks good bikes?

I'm wondering if something like that would be covered by Trek's warranty.

All you need is a little dab of this ... :thumb:

http://www.theboxotruth.com/images2/e75-5.jpg

Slip some duct tape in there and put er back together, good as new.

Ha ha ha..Yeah right...They are the only CF frames with that particular problem lol

So, you are trying to repair the frame now? Your definition of disgust must be quite different than mine.

First photos are the left side. Last photo is right.
WR needs to make friends in the performance sailing crowd. I14s etc.
Those guys eat CF repairwork for breakfast.

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.

http://img402.imageshack.us/img402/7185/dsc04500m.jpg

The flake on the face at just before 6 o-clock?

Yeah the flake. If it's just a flake, then bring the frame over WR. Otherwise, troll away.

wookie legs break treks.

pffft. I'd have torn the shell clear ****ing off. HTFU

10 pages at least.

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.