FIXED the Frame...thank god!

[will]

JV,

Your welder did a nice TIG job. Mine did not...

I took my new 856 down to the local welding shop to get a disc brake boss attached to my swingarm.

Not pretty at all. I've got it looking better, but have doubts about the metal structure where the box tubing joins the dropout casting. We shall see.

And it cost > $50!

You have been well taken care of on that frame repair.

Will

[jinder]

Ahh man, sorry to hear about your 856.  Do you have any photos?  Terry "shovelon" is the man to talk to about welding - he is a master welder.  I saw a 856 frame on ebay for $45 but there is only 3 hours left....


http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&category=98083&item=7166834795&rd=1

You could get this one...its looks excellent

[will]

Thanks for the tip... I'll pass for now. (Still digging my way out of the doghouse for "miscellaneous expenditures" on bicycle parts and skeet guns.

I'll post pics soon, but if there's damage from overheating, I won't see it untill it fails. It's possible to test, I suppose, but will just let it cure for a few weeks before stressing it out.

BOL w/ the seatpost.

Will

[shovelon]

Hey there Will,

If the  disk tab is positioned correctly you are in good shape. If the welder used high strength filler you are in good shape, and you can grind away. Cannondales are done this way. What I would do is call the weld shop and ask what about the filler. 5356 is the right alloy for the weld but 4043 alloy can work if you beveled the tab and don't grind too much off.

And this is not a high stress area, so GO RIDE!

Terry

[jinder]

I need to learn to weld!

It is a true skill, an ART!  Terry...I wish you were nearby, I would learn from you  

[pmcnic856]

Did the same thing to my 856 this weekend up in downieville CA. I hade the seat post up to high, as I always have since I bought the bike. Hopefully I will find some one who will do as good of job as you got. Did you think about adding a gusset to the frame?

[smiley=doh.gif]

[whisperdancer]

Hi Jinder.

Be sure to have it heat treated to T6.

Some while ago the head tube of my 757 started to crack. In time it got worse (any effect from the Crosslink twisting forces here??? I don't know...)

I had the tube cut off (not joking), fitted and welded a new Columbus, custom butted, aluminium tube and trated it to T6, according to K2's information.

I never had a problem after that, until I switched the 757 frame for a '97 Animal one, as the 757 has been always oversized for me...

[jinder]

Yes, it was T6, thanks for the info!



pmcnic856,  I don't have a Gusset...I got a new long post, I am riding it all the way to the end of the tube...it will never break again  

[shovelon]

More information of the welding and aging of 7005 and 6061 can be found at:

www.eastonbike.com

Click on the technical/faq header, then on the technical bullitens link, then on the fabrication link.

Terry

[whisperdancer]

Be aware that proflex 957 custom butted ProGram aluminium is a 7005 alloy...

[shovelon]

Right you are Whisperdancer.

 The 957 frames using 7005 does not need solution heat treat for hardening as 7005 is self hardening. But because it did not get the powdercoat cycle, they were probably autoclaved to induce artificial aging.

 The artificial aging is to expedite the stress relief and gross hardening for manufacturing purposes. Natural aging occurs over a longer period of time. So after a weld repair, a period of days or weeks of natural aging is sufficient to obtain a grain structure sufficient for optimal design load.

 The time factor for natural aging is related to the severity of the weld repair. A seatstay fracture such as Jinder's may need only a week for adequate aging, seeing as there was an unintended overload involved. A bottom bracket repair may need as much as a month of aging, as the fracture may have occurred because of  metal fatigue(work hardening to the brittle stage).

Terry

[jinder]

Terry your a MASTER welder!