Full Answer
Can carbon fiber bike frames be repaired?
To learn more, we spoke to carbon fiber expert, Brady Kappius. He is the founder of Broken Carbon, a premier carbon fiber bicycle repair shop in Boulder, Colorado. Kappius and his team have successfully repaired over 4,500 carbon bike frames, and they understand the material inside and out.
What is the best place to get a carbon frame repaired?
Before all else, it’s always a good idea to find out what your local shop and frame manufacturer can do for you. Calfee is the gold standard in carbon repair, with by far the longest palmares — over 5,500 frames have been through their repair shop. They’ve been at it since 2003, and have built carbon frames since 1987.
How much does it cost to fix a broken carbon pipe?
Broken Carbon is a new venture, and offers repairs of a worn area for as little as $100, or repair of a completely separated tube starting at $225. Rush delivery is available, with a turnaround time of only 24 hours in most cases, for a 75 percent surcharge.
What is the warranty on a carbon fiber frame?
Appleman offers a 10 year warranty on carbon fiber repairs. Work involving metal like adding cable stops or water bottle bosses are not covered under warranty. The warranty is transferable to a new owner with proof of the original repair. How do I know if my frame is damaged? That's a great question.
How much does it cost to fix a broken carbon bike frame?
On average a carbon repair will cost around $400. This does not include paint matching but always includes a protective clear coat finish over the repaired area. Repairing carbon damage is fairly straightforward but matching the original paint design and color can tend to be a lot more complicated.
Is it worth repairing a carbon bike?
Fixing a carbon frame is, in fact, considerably easier and more effective than trying to mend a broken alloy one, and the repair will be as strong or stronger than the surrounding material. Yes, there is a slight weight gain, but we're talking less than the difference between an aluminium and titanium bottle cage bolt.
Can carbon bike frames be repaired?
Yes, you can! The process of repairing a carbon fiber bike frame that is cracked, damaged, or split is to lay new carbon fibers and epoxy them in the same direction as the original fibers. The end result is a stronger bicycle frame than the original build at a negligible weight gain.
Can you repair damaged carbon fiber?
There are no special tools, equipment, product, or training required for repairing or replacing of a carbon fiber component. Any of the products that are currently used to repair fiber-reinforced plastics and fiberglass can be used for cosmetic repair of body panels, hoods, decks, and doors.
How do I know if my carbon frame is damaged?
With a dollar coin, tap on any suspect area and listen for a change in sound. A normal “tap” sound will become a dull thud when the carbon is broken. Gently push on the suspect area to feel if it's softer than the surrounding area.
Is it easy to damage a carbon bike frame?
Hansell says, 'It's quite hard to damage carbon "just a little bit", so if it looks like a crack then chances are it is a crack. 'Also, the elasticity of carbon fibre is usually less than the paint, so if the paint is cracked, there's a high chance there's been some kind of trauma to the carbon too. '
What is the lifespan of a carbon bike frame?
Unless they are damaged or poorly built, carbon bike frames can last indefinitely. Most manufacturers still recommend that you replace the frame after 6-7 years, however, carbon frames are so strong that they often outlast their riders.
How much does it cost to repair a frame?
The cost to fix a car frame can range from $600 to $10,000. Since it sounds like you had a minor accident, I hope the cost of repairs is on the lower end for you. For the safety of the passengers, cars these days have what is called crumple zones.
How much does it cost to fix a bike frame?
Smaller cracks (1/3 of tube diameter or smaller) are $200. Medium cracks (fractures greater than 1/3 of the tube diameter) are $300. $400 will fix major damage (missing carbon, damage greater than 6 inches along the tube. The VeloNews.com frame would likely fall into the $300 range.
How do I fix my carbon frame?
2:2617:56Can You Repair A Carbon Fiber Bike? - YouTubeYouTubeStart of suggested clipEnd of suggested clipThe first step in the process is to actually ascertain. What the damage is and perform an assessmentMoreThe first step in the process is to actually ascertain. What the damage is and perform an assessment. So sometimes the damage is quite obvious and there's big cracks and holes in your carbon frame.
Does carbon fiber crack easily?
That's because carbon fiber's incredible stiffness properties come at a price: On its own, it is quite brittle and prone to splitting and cracking. To preserve its abilities, it's suspended in a glue-like material called epoxy resin before it's molded, forming a composite material.
How do you fix a cracked carbon bike frame?
0:235:54How to repair a carbon fibre bike - YouTubeYouTubeStart of suggested clipEnd of suggested clipAttachment. The repairs will be done using a composite patch bike patch. Which is a 200 gram carbonMoreAttachment. The repairs will be done using a composite patch bike patch. Which is a 200 gram carbon fiber twill weave and a specific epoxy resin. The first thing is to send the area to be repaired. We
How do I fix my carbon bike?
The ProcessStep 1: Disassembly. Completely stripping the frame of all components — including hardware like the derailleur hanger — made it easier to work on.Step 2: Sanding. So much sanding! ... Step 3: Clean Frame. ... Step 4: Masking. ... Step 5: Make Templates. ... Step 6: Clean Work Area. ... Step 7: Cut Carbon Fiber. ... Step 8: Mix the Epoxy.More items...•
How do you fix a crack in a carbon fiber bike?
0:295:54How to repair a carbon fibre bike - YouTubeYouTubeStart of suggested clipEnd of suggested clipYou once the sanding is done you should remove the masking tape that will have been damaged duringMoreYou once the sanding is done you should remove the masking tape that will have been damaged during the sanding. And use electrical tape to protect the frame again for the repair.
How do you repair a carbon fiber bike?
7:3717:56Can You Repair A Carbon Fiber Bike? - YouTubeYouTubeStart of suggested clipEnd of suggested clipThe first thing is to remove the damaged carbon to go into this in to see whether what the extent ofMoreThe first thing is to remove the damaged carbon to go into this in to see whether what the extent of the damages. In some cases you can get delamination.
How do you fix a broken carbon bike frame?
0:004:14Carbon Fiber Bike Frame Repair UNDER $30 - DIY How To - YouTubeYouTubeStart of suggested clipEnd of suggested clipSo there's a soft spot on the frame right here and it gives just a bit when I press on it with myMoreSo there's a soft spot on the frame right here and it gives just a bit when I press on it with my thumb makes a bit of a cracking noise - I don't think you can hear it on the microphone. So first
Who repairs carbon frames?
Matt Appleman of Appleman Cycles repairs a carbon frame.
Is it safe to disconnect a bike?
Most bike manufacturers recommend against this practice – but your website (and others) claim it is very safe. Why do you think there is a disconnect?
Is carbon fiber covered?
It’s also a myth that carbon fiber needs to be “protected” or “covered” so that the elements don’ t damage it. This is false. In fact, carbon fiber/epoxy is chemically inert and doesn’t react to the elements.
Is mountain bike repair a science?
So yes, a mountain bike repair will be different than a road bike repair because the bike was (hopefully) designed to be stronger.
Is it cheaper to get a new part?
It’s cheaper to get a new part. Rims: you have so much heat, friction, and extremely high forces on very small areas that repair isn’t practical. On the other hand, disc wheels ( as in TT disc wheels) are repairable, except along the brake track.
Is carbon repair technical?
I think carbon repair as a whole is all technical and each step has its own technical aspects. I’ve been doing repairs long enough it has become second nature, but I really enjoy the breadth of knowledge required of the repair process. Diagnosing damage, paint removal, layup design, applying the layup to the frame — it’s all technical, and requires a lot of practice and skill to perform efficiently.
What to use to clean a sanded frame?
Once I was satisfied with the sanding, I thoroughly cleaned the frame with alcohol and a lint-free cloth.
What was left to do after the frame was patched and painted?
Now that the frame was patched and painted, all that was left was to put the components back on and go ride!
How much epoxy to mix with hardener?
Using a kitchen scale, I mixed the epoxy and hardener together at a rate of 2:1. Since this batch of epoxy was only going to be used for a base layer, I mixed a fairly small amount. The videos I watched and written instructions that I read all emphasized taking the time to thoroughly mix the two. The kit I used suggested five minutes of mixing.
How long does epoxy dry on rubber gloves?
Step 9: Apply Surface Coat of Epoxy. The surface coat of epoxy. The surface coat of epoxy is applied with a brush and then left to dry anywhere from 1.5 to 4 hours. You want the epoxy to be tacky when you touch it while wearing a rubber glove, but no residue should come off on the glove.
Can you repair carbon fiber handlebars?
This guide is intended to be a helpful resource for someone considering repairing their carbon frame at home. Do NOT try to repair carbon fiber handlebars, seatposts, forks, saddles, etc. Professional repair companies won’t even touch those.
Can carbon fabric snag?
Carbon fabric can easily snag on a rough surface or pick up debris from a dirty work surface. Before I rolled out the fabric for cutting, I cleaned my workbench, put away any unnecessary tools, and laid down a large, clean piece of cardboard.
Can you put carbon patches on epoxy?
Once the surface coat of epoxy was at the appropriate level of tack, it was time to lay down the carbon patches. But first, I needed to mix up another batch of the epoxy. I made about twice as much for the second batch, following the same procedure above.
How long does it take to repair structural carbon?
Structural carbon repairs can and are typically completed within a week or less from the day of arrival .
How to ship a frame to us for repair?
When shipping your frame to us for repair, please remove all parts and send only the frame. Please include in the box a description of exactly what you want us to do. Locate the damaged area and include your wishes for the paint or no paint option. Lastly, please include your name, phone number and email address and we will handle the rest.
Can you repair carbon damage?
Repairing carbon damage is fairly straightforward but matching the original paint design and color can tend to be a lot more complicated. Complex masking or multiple colors is an additional cost and quoted on a case-by-case basis.
Is carbon damage repairable?
Almost any carbon damage is repairable and we’ve seen and repaired just about all.
Can you repair a bike with paint?
Each repair is different and will require a unique layup for an effective repair. You can decide to keep the repaired area visible and add to the collection of battle wounds and stories of your bike or you can choose to treat it cosmetically, with paint, to blend in with the factory finish just like nothing ever happened.
How much weight can a UCI frame hold?
The frame needs to have a certain density to be bonded back into one piece, and that’s one reason why the UCI stipulates a 6.8kg minimum weight limit. As frames have got lighter, the tubing has got thinner, creating problems.
Does oversized tubing have more surface area?
Modern oversized tubing offers more surface area, but at certain zones of the frame — such as the bottom bracket — it is difficult to add more material.
Is carbon a good frame?
With a frame, there’s a lot of surface area to work with, but there are limitations. Carbon, with all its qualities, also has its shortfalls. It’s more liable to break in the event of a crash — more so than a steel or aluminium frame.
Can you have a carbon bike frame repaired?
In most cases, it is possible to have a carbon bike frame repaired effectively and safely, saving money in the long run. But sometimes it is not possible . If the bike is insured, then it’s hard to see why you’d take the risk.
When did carbon fiber start being used in bikes?
You didn’t really start to see carbon bikes taking off in the consumer market until the early ’90s. "The unique thing about carbon fiber is that it's very lightweight, but it’s also durable.
Why are bikes made of carbon?
There’s a reason so many modern bikes are made of carbon. Carbon fiber has some advantageous properties compared to metals like steel, aluminum, and even titanium. Brady Kappius: "Relative to other materials, carbon fiber is one of the newest in the cycling industry. The technology that brought carbon fiber to bikes really came from ...
What is the difference between a carbon fiber bike and a metal bike?
BK: "The big difference between a metal bike and a carbon fiber bike is in the manufacturing process. With a metal bike, tubes are welded together. Those tubes are usually purchased or formed, and then it’s just about joining those pieces together into a frame. "With carbon fiber, it’s completely different.
How many degrees are carbon fiber sheets?
You might have one sheet where the fibers are oriented at a 45-degree angle, one at 0-degrees, or one where it has 90-degree fibers woven together with 0-degree fibers. Those woven fibers create that typical carbon weave look people think of when they imagine carbon fiber.
What is carbon fiber used for?
Published December 05, 2019. Cycling is obsessed with carbon fiber. Carbon is used to build frames, wheels, and components. You can find it on everything from entry-level bikes to barely attainable halo rides. If you’ve spent any time talking with any opinionated cyclists, you’ve undoubtedly heard plenty of anecdotes, jokes, concerns, ...
Why do you want carbon in mountain bikes?
On mountain bikes, for example, you want some lower-modulus carbon in areas because you want the frame to take impacts better and actually have some flex to it. It’s more of a marketing term. Someone might say they have 'X-hundred Toray, high-mod whatever' carbon fiber and it really doesn’t mean as much as you think.
Is carbon fiber as strong as aluminum?
Carbon fiber is incredibly strong. But the average consumer might have the misconception that carbon fiber is not a strong as steel, titanium, or aluminum. This isn’t always the case, but Kappius explains the reason why this sort of misconception has developed.
How long is a carbon frame warranty?
Carbon frame repairs that do not require specific torque settings are covered by a 10 Year Warranty!
Is CNC carbon overbuilt?
All damages are thoroughly inspected, and repairs carefully planned and executed with a high level of workmanship. CNC carbon repairs are never overbuilt!
How much does carbon paint weigh?
Speaking of carbon, we cannot fail to take into consideration its weight: on frames that weigh about 800 grams, the paint amounts to about 140 – 180 grams , therefore constituting 17 – 22% of the total weight. Quite a lot. If we have overlapping paints, this percentage rises dramatically.
Why do manual labourers not bring carbon back to zero?
As a matter of fact, in order to do this literally means sanding down all the old paint by hand with full knowledge of the facts: the manual labourer must have some experience in order not to ruin the carbon itself. For this same reason, the use of machinery is highly discouraged. Clearly, those who skip this step save up to 4-6 hours of work per frame. The following video shows a moment of this process.
What is the purpose of a fiber filler?
Once the fiber has been checked, a “filler” is applied to fill in any discontinuities in the carbon; this has nothing to do with structural strength. Only at this point can one start to paint, and once it has gone through the oven a few times – depending on the number of colours needed – a transparent coating is applied, which can be opaque or glossy.
Is repainting a carbon frame a delicate job?
In reality, repainting a carbon frame is a time-consuming and delicate job and the cost of labour is often directly proportional to the quality of the work carried out. Let’s see why in a few simple steps and with the help of some images and videos.
Does weight matter in car paint?
As mentioned above, we are not dealing with car paint where weight does not matter and where paint can be applied abundantly to create more robustness: here we are dealing with very thin layers of paint measurable in tenths of a millimetre, which must, therefore, be spread in the most homogenous way possible. A “heavy” painting is also easily visible where the tubes connect; here the abundance of material makes certain intersections more rounded and therefore less elegant.
Can you repaint a carbon frame?
This is the longest and most laborious procedure for repainting a carbon frame, but also the most effective. Speaking of a high quality frame, such as that of carbon, it would be useless and counterproductive to carry out any other type of process just to save money and thus degrade the frame precisely in its most visible point: the paint.
