Author Topic: Cracked OZX frame (Read 8491 times)

Phillip · « **Reply #15 on:** August 21, 2003, 11:00:47 am »

Op, were those EVO frames that are "especially" prone to failure you refer to possibly used for any freeride activity? If so, I've also witnessed "big time" failure.

Dominic, that is really nice to offer your help. [smiley=beer.gif]

Old Proflexer · « **Reply #16 on:** August 21, 2003, 03:27:09 pm »

i believe i ment 'especially the frames' being aluminum suffer from metal fatigue not that the frames made of aluminum were 'especially prone' -

OP - sorry for the miscommunication

and well, yes they did seem to see a bit more adventure than the average xc bike.

Proflexman · « **Reply #17 on:** August 24, 2003, 09:52:28 am »

Hello all on this lovely Sunday evening.

Well i spoke to a fellow composite repairer and retailer who said that the use of Carbon tape was not needed on the inside if the frame as the epoxy would be good enough but that a woven roven matt would be strong enough.

So the right side has been repaired and i am finishing cleaning up the left side ready for applying the west system epoxy and glass fibre tape.

I will post a photo of the repaired side and the side ready for repair for you to look at.

The middle section will of course be carbon sheet.

Whilst i was at it i epoxied in place the BB houseing and the swinging arm tunnel.

When i am finished i intend to coat the frame in a satin semi gloss two pack lacquer.

I rode this Merlin echo today and have been reminded why i ride a full susser as i am back on the pain killers for my spine again.

The Merlin is a good bike but like one of you said to me i will go to my grave with my K2.

I will keep you posted as things go and should you need any help please feel free to ask and i will try and help. [smiley=nod.gif]

Phillip · « **Reply #18 on:** August 24, 2003, 01:37:01 pm »

Dominic,
Are you vacume bagging the repairs or just laying it up?

jedoaks · « **Reply #19 on:** August 24, 2003, 04:36:54 pm »

Proflexman · « **Reply #20 on:** August 24, 2003, 08:11:13 pm »

Its a lovely sunny bank holiday today.
Right i am not vacum bagging the laying up process as it does not need it on the inside of the frame.
But if i was going to lay a finer weave over the outside then yes i would vacum bag as that would suck the resin through the matt and then i could flat back and polish up without the need to lacuer.
Though West sysem is not impervious the ultra violet sunlight so in a hot sunny country a lacquer would be required.
I am interested to know how much i could pick up another ozx carbon frame for from the States.
I will load the pics today.

Phillip · « **Reply #21 on:** August 24, 2003, 11:26:59 pm »

Would vacume bagging make a stronger repair by pulling the resin deep into the matt? I've never worked with vacume bagging, but is the idea to eliminate all trapped air in the layup and basically just suck it all together?

It should be possible to buy an OZ frame for around $300, but you may have to watch for a while to find one. I haven't seen any for sale recently.

Old Proflexer · « **Reply #22 on:** August 27, 2003, 01:22:02 am »

still wait'n for the pics here - and check your gallery every day

when you get a chance

OP

Proflexman · « **Reply #23 on:** August 27, 2003, 04:22:09 am »

Do you ever get one of those days where things seem to gang up on you.

I put the digi cam down and moved the two halves of the frame to get a good picture and i just felt something go clunk and quick as a flash i knew i had touched the camera and even then knew it was too late to do anything except wait for it to hit the concrete and it did

It never ceases to amase me how many pecies something will disintergate into given half a chance [smiley=disbelief.gif]

So now i get the chance to buy myself another camera, spend more money

That will teach me never to under estimate chance and what it will do.

Sorry guys but your going to have to wait a little longer.

StoereVent · « **Reply #24 on:** August 27, 2003, 07:03:41 pm »

post some pictures of the broken cam too!

jeroen.

Proflexman · « **Reply #25 on:** August 28, 2003, 10:04:02 pm »

[smiley=laughing.gif] Jeroen thanks for that i think i will.
Well to update everyone.
I have repaired the inside of the frame with carbon as the standard woven roven is a tad too heavy and not quite as strong.
The inner baffle with seating lips i have removed completely and just have the orginial faces.
I then rubbed down the frame with a coarse sand paper to form a key and covered each half with a finer weave of carbon.
I then cleaned up the edges and joined both halves together.
Then i used a small grinder and a file to make sure the joined faces had no high spots and i removed the lip that runs around the outside of the frame except at the seat post and at the tube for the fork tube these i felt had to be as strong as possible.
I was unable to buy a finer weave of carbon tape to match the weave that covered the frame and a coarser weave would not be flexible enough to wrap along the seam edge so i carefully cut the required strips of carbon out of the finer weave i had and applied the epoxy to the frame around the seam edge then applied the tape to it then applied more epoxy until the mat was well soaked in resin, this i had to do in stages as i needed to keep turning the frame which was clamped and bolted where the rivets normaly go.
Before i joined the two halves together i applied epoxy to the fork tube housing and seat tube housing hence they were clamped and bolted together.
All seams are now dry and today i intend to sand down the frame untill it is smooth, along all seams carefull not to go through the epoxy otherwise the mat will be damaged, then i will apply another coat of epoxy and wet and dry that down clean up and de grease apply the decals and apply a two pack satin lacquer.

To those interested when i had cleaned both halves of the frame i should of applied a lacquer then wet and dried them and applied a wax release agent to each frame then covered each half in four layers of 450 gsm matt to make a mould that way i could always make myself more frames as and when i required them.
My only problem with that is what would K2 of said when they had found out.
Should i get hold of another large ozx/m frame i will make some moulds.

Simon · « **Reply #26 on:** August 29, 2003, 09:47:59 am »

You know my views on this Dominic from our conversation the other day, please try and make a mould I'm sure every one will agree, can't see anyone telling K2 ? they don't make it anymore, and I'm sure theres a lot out there who would like to get there hands on an Oz or even if you just had a mould for anyone unfortunate enough to of broken there beloved Oz.Simon [smiley=nod.gif]

jedoaks · « **Reply #27 on:** August 29, 2003, 01:45:02 pm »

You are badass Dominic, sounds like you know what you are doing. Be aware that K2 follows this forum, if that matters. Rich

Proflexman · « **Reply #28 on:** August 29, 2003, 08:15:27 pm »

Good morning class shall we start.

Well it took me quite a few hours sanding down the edges and the excess epoxy yesterday.
If i had of vacum bagged the frame i would of ended up with a more uniform finish but the result was very much the same.
I sanded down with 40 gritt sandpaper, this i thought to be a little coarse but it did remove all very quickly my only fear being that it would leave marks in the frame when i re applied the epoxy.
All were unfounded as i coated one side with a finishing coat and you should see how it came out, the carbon matrix of the matt shines through with a depth of colour showing off the weave and texture.
I am pleased with the result i have got and feel confident now to repair and build more frames.
I know how you feel Simon and i will contact K2 and ask how they would feel about me useing one of their frames to run a mould from then i will build them useing the finer weave of matt as this would be as strong and more pleasing to the eye and easier to work with as the frames at the mo are pressed and i am unable to do this.
The metal work for the BB and the swinging arm housing i can get made out of Ti which again will be lighter so any frame supplied to anyone will be much lighter than K2's.
I am not sure about the swinging arm this i think i will ask Mark if he can map it and make out of Ti or maybe T6 alloy.
Maybe someone else out there has insider knowlege of how they would make them.

So guys/gals i am in the market for a large ozx carbon frame.
Anyone.
You can have the first one off the line so to speak.

Old Proflexer · « **Reply #29 on:** August 30, 2003, 02:06:00 am »

i do have a couple of 'extras' either hanging or boxed in the garage. what's your plan?

disfunctional, abused units come up on occasion for sale tho'

OP

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Author Topic: Cracked OZX frame (Read 8491 times)