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We perform all our aluminium bicycle frame repairs on a welding jig table. This ensures that frame geometry and alignment return to the factory specifications.
Above is a typical welding repair that we perform on aluminium bike frames. A crack forms at the junction of the seat tube and top tube. This is a highly stressed area, especially for tall riders that extend their seat post out very far. We have found that a brace is the only way to ensure longevity. Depending on the severity of the crack or break, a double brace may be necessary.
Seen above is a break that has formed at the junction of the chain stay and the brace tube. To ensure longevity, we installed a solid aluminium bar into the original broken tube portion, allowing for a stronger overall repair. We welded together the aluminium chain stays, maintaining all critical angles and measurements.
Here we see another break that has formed at the junction of the chain stay and the brace tube. We welded up the broken aluminium parts because of the wall thickness of the parts involved. Another successful bicycle frame repair.
Another typical break at the top tube and seat tube junction. Here, the frame broke into two separate pieces. A welding repair involving a brace was the only option to save this frame. We TIG welded the repair and restored the frame rigidity.
Another aluminium bicycle frame repair involving the top tube and seat tube junction. Here the top tube broke at the edge of the factory weld - which is not at all uncommon. We welded in a top brace, which was difficult considering the small space between the top of the seat tube and the upper surface of the top tube. This was not aesthetically pleasing, but was very functional.
A simple aluminium frame repair involving a clean break on a frame upright tube. We prepped the tubes for welding and completed the welding repair.
Going from a simple aluminium frame repair above to a very complex repair involving aluminium welding and machining. Here you can see a crack in the head tube which runs through the bearing seat. After welding up the crack, we had to machine the bearing seat area back to its original dimensions and position.
Here is a second example of a complex aluminium bike frame repair requiring another unorthodox approach. You can see the seat tube has broken into two pieces in the shocks’ pivot point mounting area. The client requested us to provide a strong as well as aesthetically pleasing repair solution. We did both by inserting a solid bar down the seat tube and rosette and lap TIG welding it into place. Hand finishing was used to blend the surfaces together.
Here is a third example of a complex aluminium bike frame repair requiring a different approach. Here, as with the example above, the seat tube has broken into two pieces in the shocks’ pivot point mounting area. The client also requested us to provide a strong and aesthetically pleasing repair solution. We could not insert a bar down the seat tube as it was not straight. We TIG welded the frame as in a normal repair, but in addition, we clad the repair area with aluminium plates. Hand finishing was used to blend the surfaces together. Mission accomplished, again.
Above, we have a damaged bicycle frame sent to us from outside the country for repairs. An incident damaged this aluminium frame in the area of the chain stay and rear wheel mounting union. We aligned the broken parts on our jig table and aluminium TIG welded them back together, adding significant reinforcing to the joint.
Here we have an aluminium bicycle frame cracked in the upper seat tube area. It is interesting to note that this crack occurred despite a factory fitted frame brace. The client requested once again for an effective yet aesthetically pleasing repair to be carried out. We must mention that this result is not always possible, and sometimes an effective repair is all that is achievable. We TIG welded the original crack and reinforced the factory brace with additional aluminium plates. The result satisfied both the requested requirements.