tigerdog

I have a '98 Klein Mantra comp MTB; the derailleur hanger is bent, stripped and cracked at the bottom. Rest of the dropout, though, is straight. LBS said it could not be repaired because of the crack but offered to sell me a New Old Stock Mantra frame.

Before dropping that kind of change, does anyone have a thought to whether I could either a) straighten the hanger and use a derailleur saver insert or b) cut off the old hanger and file/mill/shape the end for a replaceable hanger? If b) can anyone suggest a suitable hanger (big selection here)?

At one time, Klein frames were guaranteed for life. Does Trek still honor this?

Advice desperately sought.

jimc101

Have you tried contacting your local Trek dealer / Trek in WI about this? they will be able to give a better answer than any forum.

Homebrew01

Picture of the damage ?

HillRider

Trek does warranty their (and their captive brands) frames for life for the original purchaser but i don't know if this will cover "accidental" damage. I agree with jimc101 that contacting Trek is the first thing to do.

I don't think there is any safe way to modify the dropout to use a replacable hanger so straightening the damaged hanger and using an insert is your best approach if you want to salvage the frame.

FBinNY 

I doubt that it's a warranty issue, as crash damage and things like stripped threads fall into the users responsibilities. However they may have a low cost repair or replacement option to offer you. So start there.

The stripping issue is easy to fix. Likewise, if it's only slightly bent, it can be straightened, but this is a matter of degree and also depends on how much and how often it's been done before.

The crack is more complex, but depending on location and extent might be repairable.

In most major cities is a shop whose mechanic is known for his ability to do impossible repairs. Ask around locally and see the right guy for advice on your options.

FastJake

If the rest of the dropout is solid the frame could probably be sold to someone (like me, hint hint) who would like to use it for single speed use.

I'd like to see pictures too.

tigerdog

I'm headed to friendly local Trek shoppe today but because their warranty excludes damage due to abuse/neglect, I'm sure they'll say a bent / cracked hanger has been abused and leave me hanging but hoping against hope someone here has had a positive experience from which I can learn and/or take heart. Really, though, I'm looking for repair options.

JohnDThompson 

Depending on the dropout, you may be able to saw off the damaged hanger and use a claw to mount a derailleur:

HillRider

I'm not familiar with that exact frame but I bet it has vertical dropouts and a claw adapter won't work. Or, like some of the Kleins had, rear entry dropouts which are equally unsuitable.

LarDasse74

As long as there is some flat surface around the axle on the outside of the dropout then a claw hanger can likely be used... not properly, but still used.

Another option would be to saw off the old hanger and have someone weld a new hanger on. On any other part of the bike I would not reccomend welding an alumnimu frame but this is not a bike deal on a derailleur hanger.

tigerdog

Here's a photo of the dropout / hanger. The crack is at about the 10 o'clock position.
You are correct - rear facing dropouts. But I'm hoping the removable hanger might do the trick. Sure seems to me the dropout could be cut off and with a little bit of dremel shaping, drilling and tapping one hole, a Wheels Manufacturing Dropout-40 hanger would bolt right up.

Thoughts? Please discuss.

Camilo

can't see the photos?

Chombi

Can'r see the pics....are you posting them up from a host site correctly?

Chombi

tigerdog

URLs updated. Try refreshing and hopefully you'll see them.

HillRider

From the picture the dropout hanger doesn't seem to be too bad. If you can align it reasonably well, I'd try a dropout saver threaded insert first. They are reasonably cheap and should work.

dedhed

Try the Trek dealer. My buddy recently had a similiar problem on a '02 LeMond. Trek gave him a new frame. Not the same model or year but an upgrade Ti/carbon. He did have his original receipt and went to 2 dealers until he found one who was much more helpful.

tigerdog

My concern was the crack. The hanger was easily realigned; I clamped the dropout with a very large c-clamp and torqued it until the clamp's threaded rod aligned nicely to a 24" socket wrench extension laid across the dropouts themselves. My concern is the crack: how much stress is the hanger under during shifting? Will the crack's added flex allow the dropout saver to wiggle around too much? I don't want to eat another derailleur or damage the wheel.

Homebrew01

Looks like another crack around 3:00 - 3:30.

If you could find a donor frame somehow, you could do a partial dropout transplant. I did one on an old Cannondale with a broken hanger.

tigerdog

I'll strip the rest of the paint off the hanger when I get back home from a business trip later this week. If it's cracked or just cracking at 3:00, then I'll have to cut it off and try to retrofit the hanger-40. Time to practice my Dremel skilz.

HillRider

The hanger sees very little stress unless you smack it against something hard. Shifting normally puts very little load on it. Also, most of the hanger savers I've seen have a significant flange on the inner side which would act like a reenforcing washer and should stabilize the crack. Some super glue forced into the crack would also help.

BoozyMcliverRot

As long as you dont shift under load.

tigerdog

and sincevthis bikevis ridden by my teen age son, this never happens...

HillRider

Even so, a rear derailleur is shifting the "slack" side of the chain so the side loads on it aren't that high.

Camilo

I understand that aluminum tubes can't be repaired, but isn't the dropout/hanger a fairly substantial piece of forged metal (as opposed to a thin, heat treated tube). And, if so, couldn't a skilled welder fix those cracks, or cut it off and transplant a new piece - and then it could be filed/shaped and re-drilled and tapped as necessary? Or would that be impossible to do without damaging the structure of that part of the frame?

Just wondering.

Homebrew01

If it was mine, I would TIG weld the crack. See post #18
However, not everyone has welder access.