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Cracked Carbon Frame

Old 02-27-17, 07:20 PM
  #1  
SCooledge
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Cracked Carbon Frame

I have a 5 year old Cannonade Synapse Carbon. Dropped it last year and put a small ding in the top tube. Area around the ding began to delaminate over time. That small ding has now spread to a crack running halfway around top tube.. Tapped a quarter on the area and got the thud noise around crack, you can also feel a soft spot on the top tube. Emailed a couple companies and they all want 350-500 to correct it. Add shipping both ways of bike and I'm at the cost of just buying a very nice used undamaged frame and moving over all my components to the new frame. Does anyone know of any other options I may have with my damaged frame?
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Old 02-27-17, 07:25 PM
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Wall art!

If you don't want to go down the repair route due to it being cost ineffective, replacing with a new (to you) one is really the only option.
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Old 02-27-17, 07:32 PM
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Something like


It's been done before:

Last edited by AnkleWork; 02-27-17 at 07:53 PM.
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Old 02-27-17, 07:37 PM
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Old 03-23-17, 02:19 PM
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Does it have a 4 rivet front derailleur hanger?

If so, I'd buy the hanger off you, or the whole frame just for that part. LMK Thanks, Paul
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Old 03-23-17, 03:00 PM
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Originally Posted by AnkleWork
Something like


It's been done before:

That should hide all the dangerous cracks nicely
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Old 03-23-17, 03:16 PM
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There are shops that will "splint" a damaged CF frame, and the cost should be much less that what you're being quoted. Of course, this would have been a better option before you let a serious crack propagate, so that option may be off the table, depending on th details.
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Old 03-24-17, 12:56 AM
  #8  
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Originally Posted by coominya
That should hide all the dangerous cracks nicely
Structurally, it can be fine. The big challenge in doing CF repair is to get the transition from base material into repair as strong as the base material. But with enough of an overlap, that is easily done.
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Old 03-24-17, 04:12 AM
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The other option, of course, is to snag a good used frame off of E-Bay, or your local Craigslist.

Then throw your old frame back up on E-Bay, with full disclosure.

Do a price evaluation on selling minimally busted frame with or without the fork (look at SOLD listings)

You may well be able to recover half the cost of the replacement frame.

Are you the original owner of the Cannondale? Many manufacturers have a crash replacement policy. Generally something like a 20% discount from a new frame. Anyway, it might be worth talking to Cannondale too.
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Old 03-24-17, 08:38 AM
  #10  
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If you are the original owner, Cannondale may have a "crash replacement" policy and would sell you a new frame at a significant discount. I'd try them first before trying any repairs to your current frame.
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Old 03-24-17, 08:48 AM
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Look up West Systems Epoxy. They sell the epoxy, of course and carbon fiber. It can be repaired depending upon you skill and the cosmetic results that you would like to see when finished.
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Old 03-24-17, 08:53 AM
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I didn't notice it at first glance, however, that Trek in the picture above now has a Bamboo down tube, seat tube and seat post.
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Old 03-24-17, 11:20 AM
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One thing that never comes up in these threads is: If repaired will it ride the same? All the manufacturers make big deal about design, including fiber orientation, strength where needed, etc. It would seem that slapping a bunch of fiber/resin on would change this

Anyone have first hand knowledge?

I would like to think that a professional fix by the likes of Calfee would have minimal impact on ride, handling, etc.

I would also expect non professional fixes to have high likelhood of impacting ride. but that is just what I would expect, not fact
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Old 03-24-17, 11:35 AM
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Any good/safe repair will be overbuilt and stiffer in this localized area, so the ride characteristics may change somewhat, but I doubt you would notice the difference.

I think you either: (1) Decide you just want to get back on the road at least cost so you do a serviceable, but probably cosmetically-challenged repair (that may or may not slightly change the ride characteristics and will make the bike slightly heavier); or (2) decide you want the bike back to "like new" condition so you replace the frame. Trying to get the result of (2) by a repair is not cost effective.

If my bike, I'd replace the frame and either wall-art it (if it holds nostalgic value) or sell it for whatever it would bring (with full disclosure). Somebody else may be happy to try a shade-tree repair and/or not care as much how it looks/rides.

- Mark
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Old 03-24-17, 12:06 PM
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Originally Posted by Velo Mule
I didn't notice it at first glance, however, that Trek in the picture above now has a Bamboo down tube, seat tube and seat post.
And there's this:



I'd just prep it well, lay-up a nice thick scab, do nothing cosmetic, and ride proudly.
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Old 04-05-17, 11:20 PM
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$350-500 feels like a good deal to me given the work that has to go in.

- Disassemble
- sand it to raw carbon
- shape both sides and prep for layup
- 4-5 shaped layups building up a wider patch, using a high quality ($$) resin (not West Systems or Tap)
- fill-sand-fill-sand-etc to get it smooth
- mask, primer, paint, match decal/design, clearcoat
- Reassemble

That's a lot of labor. Totally agree with others that buying an ebay replacement may be your best move. I have a Scott Addict that's got a crack in the top tube...still riding it as a rain bike as long as the crack doesn't propagate. Then who knows. Probably the shredder.
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Old 04-10-17, 12:27 PM
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Originally Posted by SCooledge
I have a 5 year old Cannonade Synapse Carbon. Dropped it last year and put a small ding in the top tube. Area around the ding began to delaminate over time. That small ding has now spread to a crack running halfway around top tube.. Tapped a quarter on the area and got the thud noise around crack, you can also feel a soft spot on the top tube. Emailed a couple companies and they all want 350-500 to correct it. Add shipping both ways of bike and I'm at the cost of just buying a very nice used undamaged frame and moving over all my components to the new frame. Does anyone know of any other options I may have with my damaged frame?
The only company I'd trust in a frame repair for carbon is Calfee.

They are reasonable.

Then again I don't advocate that people ride carbon frames. Vintage Cannondale, Morgul Bismark, and Klein frames climb better, are more durable, handle better and are just "faster"
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Old 06-05-19, 07:20 AM
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Originally Posted by squirtdad
One thing that never comes up in these threads is: If repaired will it ride the same? All the manufacturers make big deal about design, including fiber orientation, strength where needed, etc. It would seem that slapping a bunch of fiber/resin on would change this

Anyone have first hand knowledge?

I would like to think that a professional fix by the likes of Calfee would have minimal impact on ride, handling, etc.

I would also expect non professional fixes to have high likelhood of impacting ride. but that is just what I would expect, not fact

Very good point. While you can do a DYI carbon repair or even pay hundreds for a carbon repair specialists to repair your bike it simply will never be the same since the carbon weave, lay, and resin will all be different. Sometimes the carbon repair is weaker than the original bike and sometimes it's actually stronger making the feel and even performance of the bike different.

Personally while carbon can be repaired I kind of look at it as a disposable frame and would just try and get a new frame or even new bike to be safe. Probably not what anyone wants to hear. Otherwise I would look into what it would cost for the manufacture to replace since they often provide discounts on damaged frames.
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Old 06-05-19, 10:05 AM
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carbon hand layup is labor intensive, that;s why most are made where labor costs are lower..

Remember the pros have a truck full of spare everything..

and so racer may have a new bike to start next day's stage on , when team mechanics find flaws in them..


feeling crafty?

I expect bamboo bike frame building techniques could be used and then buy pre made carbon tubing...
or wind your own ..

see vacuum bagging .. a way to get the air bubbles out of the resin, while it's wet & not yet cured..




...




....

Last edited by fietsbob; 06-05-19 at 10:21 AM.
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Old 06-05-19, 10:11 AM
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Clue: zombie.
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