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Old 11-22-22, 02:34 PM
  #13  
FBinNY 
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Location: New Rochelle, NY
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Bikes: too many bikes from 1967 10s (5x2)Frejus to a Sumitomo Ti/Chorus aluminum 10s (10x2), plus one non-susp mtn bike I use as my commuter

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I don't know about retail availability, but there are structural urethane (and other) foams made for applications like this. I wouldn't trust them for a downtube, but given that both the loads and potential consequences are low, that might be the kind of solution you're looking for.

Otherwise, I'd lean to some kind of exterior wrap reinforcement, then do the same on the opposite side for cosmetics.
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