Frame Repairs - Chain stays, seat stays & swingarms - Dual suspension

  1. This is what we call a
    This is what we call a "horseshoe" gusset. We developed this form of gusseting especially for broken stays on full suspension bikes. Most chain stays seem to break just behind the bottom bracket and regardless of whether it's totally snapped or a tiny crack, it's extremely likely we're going to repair it using this method. Why? Well, because we've done it hundreds and hundreds of times... and we know it works.
  2. One very important thing to keep in mind is that no two frame repairs are ever the same. Here's some more examples of our
    One very important thing to keep in mind is that no two frame repairs are ever the same. Here's some more examples of our "horseshoe" gusseting and it's pretty obvious that even though the principal is the same, we always have to design and hand make every single gusset for every single repair.
  3. And if you ever needed proof that all our gussets and repairs are individually hand-made... this is one of the many
    And if you ever needed proof that all our gussets and repairs are individually hand-made... this is one of the many "asymmetrical" stays we've repaired over the years. Not only are the gussets for these repairs totally unique, they always end up with more bends and curves than a box of snakes.
  4. If the break is at the back end of a stay then it needs something totally different to the
    If the break is at the back end of a stay then it needs something totally different to the "horseshoe" gusseting shown above.
  5. We often need to explain to customers that in general it's impossible to repair a metal frame so that it's structurally stronger than it was to start with AND looks exactly like it did when it left the factory. Here's a factory original swingarm marked where it's cracked.
    We often need to explain to customers that in general it's impossible to repair a metal frame so that it's structurally stronger than it was to start with AND looks exactly like it did when it left the factory. Here's a factory original swingarm marked where it's cracked.
  6. This is the same swingarm as in the above photo but this one has been repaired. It really doesn't look that much different, but seriously, there's really no point to repairing your frame so it's ONLY as strong as the original. After all... the original broke. We're certainly not going to turn your bike into a monster, but there's almost always going to be some form of gusseting designed into the repair for strength.
    This is the same swingarm as in the above photo but this one has been repaired. It really doesn't look that much different, but seriously, there's really no point to repairing your frame so it's ONLY as strong as the original. After all... the original broke. We're certainly not going to turn your bike into a monster, but there's almost always going to be some form of gusseting designed into the repair for strength.
  7. Occasionally the planets align and we ARE able to do a completely invisible repair while maintaining or increasing strength. This Orange swingarm broke in exactly the right spot for a completely
    Occasionally the planets align and we ARE able to do a completely invisible repair while maintaining or increasing strength. This Orange swingarm broke in exactly the right spot for a completely "internal" repair and gusset.
  8. Sometimes one break can lead to others and make a repair more expensive. This GT
    Sometimes one break can lead to others and make a repair more expensive. This GT "finished the race" after it broke, but doing that caused another two cracks (see the arrows) and the need for two completely different repairs on the one piece of frame.
  9. The owner of this older Giant didn't just want his chain stay repaired... he wanted it
    The owner of this older Giant didn't just want his chain stay repaired... he wanted it "bullet-proof". We were happy to oblige.
  10. Bearing
    Bearing "clamps" like this are easily broken if over tightened. They can't simply be welded back together. In this case we made a spring steel gusset that fitted around the clamp and gave something to tighten against.
  11. This Rocky Mountain totally destroyed itself at the swingarm pivot. Rather than replacing the fairly ordinary system that came from the factory, we built a totally new pivot point with solidly held bearings rather than clamped retainers.
    This Rocky Mountain totally destroyed itself at the swingarm pivot. Rather than replacing the fairly ordinary system that came from the factory, we built a totally new pivot point with solidly held bearings rather than clamped retainers.
  12. Another example of a bearing retaining clamp that can't work if it can't be tightened. This was a completely non-welded repair where we built a block into the back of the pivot point for the retaining clamp to tighten into.
    Another example of a bearing retaining clamp that can't work if it can't be tightened. This was a completely non-welded repair where we built a block into the back of the pivot point for the retaining clamp to tighten into.
  13. Almost a horseshoe gusset, except it's laid vertically and actually cuts <B><I>through</I></B> the yolk of the chain stay. This was simply because the design of the stay dictated the design of the repair.
    Almost a horseshoe gusset, except it's laid vertically and actually cuts through the yolk of the chain stay. This was simply because the design of the stay dictated the design of the repair.
  14. Before and after swingarm with
    Before and after swingarm with "webs" added over the radius of the leading edge and a gusset fitted under for stiffness.
  15. Asymmetrical swingarms present unique problems in that any gussets we make have to fit on and to a number of different planes lying at differing angles to each other..
    Asymmetrical swingarms present unique problems in that any gussets we make have to fit on and to a number of different planes lying at differing angles to each other..
  16. Got a problem with a broken and/or stuck bearing? We can remove it for you.
    Got a problem with a broken and/or stuck bearing? We can remove it for you.
  17. A perfect example of how unobtrusive a repair really can be. This Orange swingarm is fully gusseted on both sides and you'd hardly pick it.
    A perfect example of how unobtrusive a repair really can be. This Orange swingarm is fully gusseted on both sides and you'd hardly pick it.
  18. This Santa Cruz seat stay broke twice and was welded up twice before it finally came to us. That was 5-6 years ago and we haven't heard back from the owner since so we assume it held up just fine.
    This Santa Cruz seat stay broke twice and was welded up twice before it finally came to us. That was 5-6 years ago and we haven't heard back from the owner since so we assume it held up just fine.