Can A Crack In Carbob Bike Frame Be Safely Fixed

We recently visited Paint My Bike, a carbon repair and painting specialist, to learn more about how carbon repairs are done. Flick through the gallery to see what we learned — We recently visited Pigment My Cycle, a carbon repair and painting specialist, to learn more well-nigh how carbon repairs are done. Picture through the gallery to come across what we learned

*Colin Levitch / Firsthand Media*

A cracked frame doesn't necessarily mean it needs to be replaced – quite a lot of damage can fixed — A cracked frame doesn't necessarily mean it needs to be replaced – quite a lot of damage tin can fixed

*Colin Levitch / Immediate Media*

First the paint is sanded back to determine the extent of the damage — First the paint is sanded back to decide the extent of the damage

*Colin Levitch / Immediate Media*

With the paint removed we can see the size of the crack — With the pigment removed we can see the size of the crack

*Colin Levitch / Firsthand Media*

The repairers at Paint My Bike like to use 'pre-preg' carbon fiber sheets. Pre-preg means the carbon matrix is already 'pre-impregnated' with the correct amount of epoxy resin — The repairers at Pigment My Wheel similar to apply 'pre-preg' carbon fibre sheets. Pre-preg ways the carbon matrix is already 'pre-impregnated' with the correct amount of epoxy resin

*Colin Levitch / Immediate Media*

The first layer of the repaired layup is twill weave carbon which is used to strengthen the area — The first layer of the repaired layup is twill weave carbon which is used to strengthen the surface area

*Colin Levitch / Firsthand Media*

To insure the repair is strong another layer of twill forms the next layer of the layup — To insure the repair is strong another layer of twill forms the adjacent layer of the layup

*Colin Levitch / Immediate Media*

Finally the repair is finished with unidirectional carbon in an attempt to match the the original layup

*Colin Levitch / Immediate Media*

Pre preg carbon needs to be refrigerated as even at room temperature the resin begins to cure — Pre preg carbon needs to be refrigerated equally even at room temperature the resin begins to cure

*Colin Levitch / Immediate Media*

While the team at Paint My Bike prefers to use pre-preg carbon, if need be they can do it the old fashioned way — While the squad at Paint My Cycle prefers to use pre-preg carbon, if need be they can do it the old fashioned way

*Colin Levitch / Immediate Media*

In an effort to make their repairs completely invisible Paint My Bike will even make moulds that will match dimpling and other patterns on frames and wheels — In an attempt to make their repairs completely invisible Paint My Bike will fifty-fifty brand moulds that will match dimpling and other patterns on frames and wheels

*Colin Levitch / Immediate Media*

For larger tube section repairs, they'll fabricate moulds to match tube shapes

*Colin Levitch / Firsthand Media*

Here's the repair from the mould we just showed you — Hither's the repair from the mould we just showed you

*Colin Levitch / Immediate Media*

This Madone came in with damage from a roof rack. Although there was damage on both sides, it did not require a full section of the tubing to be removed — This Madone came in with harm from a roof rack. Although there was damage on both sides, it did not require a full section of the tubing to be removed

*Colin Levitch / Immediate Media*

Here you can see the repair in progress from the inside, but also the joint where the frame sections were bonded together during manufacturing — Here you can run into the repair in progress from the inside, but as well the joint where the frame sections were bonded together during manufacturing

*Colin Levitch / Firsthand Media*

For a repair like this one, Paint My Bike fabricates custom air bladders to support the inside wall of the repair and squeeze out any extra resin — For a repair like this 1, Paint My Bike fabricates custom air bladders to back up the inside wall of the repair and squeeze out any extra resin

*Colin Levitch / Immediate Media*

The carbon curing oven is even equipped with a compressor, which is attached to the bladders to keep them inflated through the curing process — The carbon curing oven is even equipped with a compressor, which is attached to the bladders to go on them inflated through the curing process

*Colin Levitch / Immediate Media*

There's a few additional tricks of the trade Paint My Bike does from here, which we can't show you — In that location's a few additional tricks of the trade Paint My Cycle does from here, which we can't bear witness you

*Colin Levitch / Immediate Media*

With the repair fully prepped the bike is put into a large oven so the resin can cure — With the repair fully prepped the bike is put into a big oven so the resin can cure

*Colin Levitch / Immediate Media*

It's hard to see but this is a resin curing schedule. It's possible to crank the oven up and cure a repair in an hour, but it may ruin the paintwork and decals on the bike. Paint My Bike usually opts to bake repairs overnight — Information technology's hard to run into only this is a resin curing schedule. It's possible to crank the oven upwards and cure a repair in an hour, but it may ruin the paintwork and decals on the bike. Paint My Bike usually opts to broil repairs overnight

*Colin Levitch / Immediate Media*

We spotted a few hidden gems around the Paint My Bike workshop — We spotted a few hidden gems effectually the Paint My Bike workshop

*Colin Levitch / Immediate Media*

Some carbon repair outfits don't like to do paint and will only apply a clear coat to protect the resin from UV degradation

*Colin Levitch / Immediate Media*

One of the more common repairs that comes in are chewed up dropouts — I of the more mutual repairs that comes in are chewed up dropouts

*Colin Levitch / Firsthand Media*

So Paint My Bike had the machine shop next door make up some alloy dropout protectors — So Paint My Bike had the machine shop side by side door brand upward some blend dropout protectors

*Colin Levitch / Immediate Media*

There's a fair few discarded 'franken frames', which Paint My Bike will borrow hard to mould sections of tubing and test paint colours

*Colin Levitch / Immediate Media*

For repairs where a section of tubing is removed, Paint My Bike uses a frame building jig to ensure there are no changes in geometry — For repairs where a section of tubing is removed, Pigment My Bike uses a frame building jig to ensure there are no changes in geometry

*Colin Levitch / Immediate Media*

The shop also gets a lot of crushed steerer tubes in for repair. As a standard repair would be extremely difficult, Paint My Bike had the engineering shop next door machine these alloy supports, which are bonded into the top of the steerer where the stem clamps the tube — The shop too gets a lot of crushed steerer tubes in for repair. As a standard repair would exist extremely difficult, Paint My Bike had the engineering shop next door auto these alloy supports, which are bonded into the tiptop of the steerer where the stem clamps the tube

*Colin Levitch / Firsthand Media*

This frame came in for a Di2 conversion. If you look really close you can see where Paint My Bike knocked off the cable guides — This frame came in for a Di2 conversion. If you expect actually close you tin run across where Paint My Bike knocked off the cable guides

*Colin Levitch / Firsthand Media*

With the Cannondale we saw earlier set aside because it needed hours in the oven to cure, we headed over to the spray booth to see some frames being finished — With the Cannondale we saw earlier ready aside considering it needed hours in the oven to cure, we headed over to the spray booth to come across some frames beingness finished

*Colin Levitch / Immediate Media*

This is what the repaired section of carbon looks like fresh out of the curing oven — This is what the repaired section of carbon looks similar fresh out of the curing oven

*Colin Levitch / Immediate Media*

Before the bikes are painted they're sanded and then masked — Before the bikes are painted they're sanded and so masked

*Colin Levitch / Firsthand Media*

Instead of masking tough areas like bottom brackets and dropouts, custom-cut vinyl dots are used

*Colin Levitch / Immediate Media*

Looks like there's a The Walking Dead fan at Paint My Bike who's pretty good with an airbrush — Looks similar in that location's a The Walking Expressionless fan at Paint My Bike who's pretty practiced with an airbrush

*Colin Levitch / Firsthand Media*

Paint My Bike uses ceramicclear coats to finish off all its jobs, which need to be applied in a clean environment and then baked off. The team also do touchups on cars occasionally — Paint My Bike uses ceramicclear coats to end off all its jobs, which demand to be applied in a clean surroundings and so broiled off. The team also exercise touchups on cars occasionally

*Colin Levitch / Immediate Media*

First a clear sealer is applied to the repair — First a articulate sealer is applied to the repair

*Colin Levitch / Immediate Media*

Then the bike goes back in the oven to cure the sealer — Then the bicycle goes dorsum in the oven to cure the sealer

*Colin Levitch / Firsthand Media*

When Paint My Bike told us it could match any paint colour we were dubious – then they showed us their paint mixing room — When Paint My Bike told united states it could match any paint color we were dubious – then they showed us their paint mixing room

*Colin Levitch / Immediate Media*

While the sealer is curing, vinyl decals are printed, which will be used when painting logos on the frame — While the sealer is curing, vinyl decals are printed, which will exist used when painting logos on the frame

*Colin Levitch / Immediate Media*

All the decals are printed in-house, and they've got pretty much every logo and font on file

Colin Levitch / Immediate Media

Somebody wanted Mighty Mouse on their bike

*Colin Levitch / Immediate Media*

The team always print a couple of extra logo decals just incase one gets put on crooked

Colin Levitch / Immediate Media

While we were waiting for the paint cure we went to the bike graveyard – 10 points if you can guess what this frame use to be — While we were waiting for the pigment cure we went to the bike graveyard – ten points if you can guess what this frame use to be

*Colin Levitch / Firsthand Media*

When frames come in the damage can be assessed under an electronic microscope — When frames come in the harm tin be assessed under an electronic microscope

*Colin Levitch / Firsthand Media*

Here you can see the trouble spot — Here you can see the problem spot

*Colin Levitch / Immediate Media*

The Focus is out of the curing oven and ready for its next coat of paint

*Colin Levitch / Immediate Media*

Remember those vinyl dots?

*Colin Levitch / Immediate Media*

To perfectly match the other seatstay, two different black plaints are applied — To perfectly match the other seatstay, 2 different blackness plaints are applied

*Colin Levitch / Immediate Media*

Side by side the logo decal is applied

Colin Levitch / Firsthand Media

And then airbrushed

*Colin Levitch / Firsthand Media*

Unfortunately the logo that Pigment My Bike had on file hadn't been updated in awhile and didn't friction match the ane on the other side, so it needed to be repainted

Colin Levitch / Immediate Media

The aerospace approved tool for determining if the carbon components on a airplane are damaged. They work pretty well on bikes too — The aerospace approved tool for determining if the carbon components on a airplane are damaged. They piece of work pretty well on bikes besides

*Colin Levitch / Immediate Media*

Carbon fibre is a bit of a wonder material in the cycling world. It'southward lightweight, and depending on the layup can be tuned to be potent on ane axis, and noodly on another. It can also exist moulded into radical shapes to cheat the air current.

Unfortunately for such a cycling manufacture mainstay, the loftier-modulus carbon used in wheel frames and components is quite brittle, despite its loftier tensile strength. Designed to handle forces on a certain axis, a abrupt touch on from a different management, say from a crash, has the potential to cause serious damage.

Accept a look through whatsoever secondhand bike site and you'll find pages of late model carbon frames with cracks, broken seatstays, and crushed carbon parts. Fortunately though, if you've got a cleaved cycle all may not exist lost – because quite a lot of damaged carbon fibre tin can be repaired.

Here you can see the repair in progress from the inside, merely as well the articulation when the frame sections were bonded together during manufacturing:

You tin can see the spot where this frame was bonded together at the manufacturing plant. You tin likewise come across the actress filler material used in the joint

Corking to find out more than, we were pleased when Australian repair shop Paint My Bike invited BikeRadar behind the scenes to see how its team breath life back into browbeaten and dilapidated rides.

"When you call back about it, about frames are moulded in pieces and so bonded together. We do substantially the same thing when we're repairing a frame," explains Gary McDonald from Australian repair store Paint My Cycle.

"You'd be surprised how many integrated seatposts cut too curt we get from bike shops. We've even had quite a few frames come in for repair, and as we sand the pigment off we detect repairs that expect like they've been done before the bike ever left the manufacturing plant."

Fixing a carbon frame is, in fact, considerably easier and more than effective than trying to mend a broken alloy 1, and the repair will be as stiff or stronger than the surrounding material. Aye, there is a slight weight proceeds, simply we're talking less than the difference between an aluminium and titanium bottle cage commodities.

Even meliorate, composite repair specialists that fix upward your injured steed tin too seamlessly match paintwork and decals, leaving even the most scrutinising eyes none the wiser.

Seamless repairs

Housed in a rather industrial looking area, and hidden inside an unassuming blue building, Paint My Wheel has a fully outfitted composite repair facility as well as – likeits proper name suggests – a loftier-end spray booth.

"Every repair we do, nosotros want to exist seamless both in paint only also in tube shape and thickness," McDonald tells BikeRadar. "Not only do we want to avert that big black ball of carbon at the repair site considering it'south ugly, merely the mass of textile creates a weak point on either side of the repair."

There isn't a whole lot on a bike that cannot be repaired, and a quick await around the workshop reveals everything from classic frames from the early on days of carbon fibre, to bikes that couldn't be more than than a week erstwhile. Damage ranges from crushed steerer tubes to broken forks and sheared seatstays. Plenty of bikes have sustained harm from roof racks.

With the paint removed we can see the size of the crack:

Your broken frame can probably be fixed

For each repair as the paint is sanded back to determine the extent of the damage, the layup is besides visually assessed and volition be matched where possible. That said, concessions in creating an identical layup volition exist made to ensure a strong repair, and McDonald explained that cross woven twill carbon is sometimes used in place of unidirectional, "so at that place are fibres in more directions with less layers"

Equally the layup plays a major factor in the ride quality of a carbon frame, y'all'd remember removing or replacing a piece would make a noticeable difference. Paint My Bike worked extensively with at present defunct Aussie pro team Budget Forklifts, fixing all manner of damage on team bikes, and McDonald and crew would quiz the riders to meet if they could option upwardly any difference.

"Not a unmarried rider could experience a difference in ride quality, even after sizable repairs," McDonald says.

Your cycle isn't a plane

When you enquiry carbon repair, oftentimes you'll find outfits using ultrasound machines for 'ultimate accurateness' in diagnosing the extent of the impairment to your frame. This method is used in the aerospace industry, when the failure of a few fibres could mean the deaths of hundreds of people. There's a few repairers employ this method, and even Coulee says it puts bikes through a scanner when they come dorsum for warranties, simply co-ordinate to McDonald that's non necessarily the all-time method for determining the damage to carbon bikes.

"With ultrasound it'due south very hard to pick up cracks – it more often than not finds voids and delamination. From our feel information technology also can't tell the difference betwixt filler and a void," he says. "Almost every bike manufacturer uses filler between joins and over imperfections in the frame, and these show up as voids on ultrasound. Many brand new frames will fail an ultrasound test, a bicycle is not a aeroplane and they are not manufactured to the same standards."

The aerospace canonical tool for determining if the carbon components a plane is damaged. they piece of work pretty well on bikes too:

This is the aerospace approved tool for finding harm to carbon fibre

"The aerospace approved method for finding damage to carbon fibre is an acoustic tap hammer. If you go down to the airport right now you'll notice engineers tapping around looking for damage." McDonald says.

If we learned one thing from the day, information technology's that in that location's no sense crying over frayed fibres and cracked tubing – find out how to get them fixed. Bank check out the mega gallery to a higher place to find out more well-nigh carbon repair.

*This is non a 'How to' article, nor is it comprehensive in the techniques used as each repairer has their ain method, and in that location were a few things that the staff at Pigment My Bike wanted to go along under wraps.