We hacksawed a carbon frame so that we could try to fix it | Syd Fixes Bikes

[@sydfixesbikes]

Hi friends! We have been getting questions about this video since you saw me sawing apart a bike on our channel trailer and it's finally here! Check back in a few weeks (or better yet, subscribe 😉 ) to see the final product. If you have a broken carbon frame that needs professional help, check out bit.ly/brokencarbon

[@andyb438]

Do you have any videos on minor paint damage on a carbon frame? Without painting the whole frame?

[@leonbond9275]

The look of Devilish happiness in Syd's eye as she "Broke it some more" was Gold!!!

[@freerangemtb]

It's really nice to know that there is a company out there (I'm sure more than one) that can do permanent repairs to carbon bikes. I have wondered what would happen if either my Giant road bike or my Trance had a break. My Trance is covered at least for another year by Giant's 2-year no-questions-asked carbon warranty, but my Defy is too old for that, and while I don't anticipate doing anything that will break the bike that doesn't mean I won't end up with a broken bike one day (hopefully, whatever breaks the bike doesn't break me). It's so nice to see that someone out there is doing these kinds of repairs. And I want to thank you, Syd, for these videos. Watching you do these repairs and maintenance tasks has really helped me feel confident in tackling my own repairs and maintenance. Because of you, I now have some really good quality tools, materials, and most importantly a cool shop apron! I've recently taken on the task of rebuilding my Fuse hardtail, and it's been a blast. I've watched several of these videos multiple times in order to get an idea of what is involved in the different tasks I'll need to tackle. Thank you! Stay upright and keep the rubber side down!

[@AndrewBlucher]

I have a little story about a Giant Defy ... A customer of mine had one of the first model, about 10 years old. I have serviced it a few times, the headset never needed adjusting. But last service, when I checked the headset there was sth wrong. When I took it apart I found a bulge in the CF steerer. Oops. Potentially fatal if it fails. After several months of haggling with Giant, because they didn't have a replacement fork for that old model, they have replaced my customer's ENTIRE frame! It took them some months. But it's an entire current model Defy. Nice one, Mr Giant!

[@vbBegin1957]

make sure to renew your coverage in case something goes wrong

[@dugldoo]

Ya need an N95 particulate respirator for sawing, drilling, sanding, etc of carbon fiber, metal, wood, etc., and forced ventilation to the outside.

[@Niidea1986]

Tip: spray soapy water in order to prevent carbon powder from flying into the air.

[@wiredrabbit5732]

I studied composites at uni, and work in a industry that is on the leading edge of composite tech (carbon fibre is a type of fibre used in composites) In school, we called carbon, black fiberglass. In our business, we have electronic crack checkers and technicians who do nothing else. A slight crack and we just throw it away. But it can be repaired. It is just that easy. It'll be hard to get it to the same strength/stiffness and weight of the original (The pros will have the skills to ensure it's as close as can be). The length of overlap has to be significant (depends on the carbon weft), you have to get ALL the paint off. The type of resin used in that patch which sets quickly is very weak. The longer the set the stronger. So, if at the shop, look at something like system 3 resin. Done well it should compressed to ensure there are no voids and ideally heated (that's what we use autoclaves for) Yes, there is a lot to learn (a year of Uni to start) but yeah. Go for it.

[@wallacefreedom76]

Cracked my carbon fiber frame right at the top tube, near the seat tube. It was just a crack, not completely separated. Bought a carbon repair set off Amazon, which contained 2 or 3 (can't remember exactly) different carbon fiber weaves (unidirectional and others) and an epoxy mix. I've ridden it hard for a full season and very impressed. I'm not worried at all that it will break. Very happy to have saved my bike.

[@falcoperegrinus82]

What kit off Amazon was that specifically? Thanks!

[@kenny83081]

I'm an A&P (aircraft technician) and depending on how new the aircraft is there is a lot of what we call composite components (carbon fiber, Kevlar, fiberglass) on aircraft. They can be one material or a combination of them depending on the application. Fan blades on some turbine engines are composite and they turn at 10s of thousands of RPMs. Cool quick fix.

[@mikecarter6758]

Broken Carbon fixed my son's old 26" mtb. He knows his stuff!

[@sydfixesbikes]

Awesome! We can't wait to see this frame after he fixes it!

[@marciolprado1]

DO NOT DO THIS WITHOUT A SPECIALIST'S FOLLOW-UP.

[@scp.engineering]

Where is the professionell repair video?

[@LoneWolF-mj2sj]

Nice.. You were fearless & held it together during the hole "emergency". I started writing as I was still watching and it felt as if it was real time.If that happened to me out somewhere nowhere close I might of.. I don't even want to say it ( carry the bike all the way back to my car) awesome video thought. Amazing fix,, Sweet test ride, Job well done.

[@JustAGlitchFL]

I think I saw somewhere that you can use a spray bottle to spray water, which will keep the dust down, when cutting carbon bats and such.

[@richardhaselwood9478]

That's what Park Tools do on their videos. Spray bottle with soapy water. Looks like an elegant solution

[@randomcontent2469]

Me: watching video (6:04) Mom: walks into my room Me: volume doooooown

[@rossg9363]

Hahaha 🤣

[@justin_time]

It took me days to be able to click on this video. So glad to learn the sawing was done on an already broken bike! Phewf! Cool video!

[@feldybikes]

11:32 sweet jump! You got like 3 feet of air that time.

[@sydfixesbikes]

😂

[@808surferboy3]

What happen to the professional repair video?

[@oliverblack5477]

I'm going to make a bike out of PVC pipes and this carbon repair stuff and have my own carbon fiber bike XD

[@brentonandatent1767]

Thanks for the video, I just repaired my aluminum frame using this stuff. Wish I could post the pics...seat tube and top tube were cracked all the through and all the way around, was riding with hose clamps holding it together because there aren't any new bikes due to covid, rides like new, for how long Idk but at least I'm back on my bike.

[@4961Studebaker]

Aviation Nerd! - watch a doc about the Boeing 787 Dreamliner and the robotic machinery that wraps / creates the carbon wrap around the fuselage. Great video team.

[@Zee-hl5iu]

not to be that guy but that kind of mask wont protect you from carbon fibers in the air..get an m3 n95

[@campbikerepeat3862]

Doesn’t work for Covid either.

[@raul0ca]

I think the carbon fiber cut off with a hacksaw will still have a significant amount of resin on it decreasing the chance that it will stay airborne. Now if it was cut using a dremel...

[@Xenon720]

I would also recommend spraying water on it to keep the debris down.

[@EstonianBerserker]

Or vacuum

[@kjeldschouten-lebbing6260]

@@raul0ca You also don't want epoxy particles in your lungs.

[@andrenighthawk4431]

Content gets keeps getting better!

[@matthieudanneels5122]

I've repair my aluminium frame this way, a crack in my rear right base, not a pipe but a piece of cnc and only cracked at 50%. It's was a kit with resin apart and I use glass and carbon fiber. It holds for 5 mounths... 🤞

[@sydfixesbikes]

Wow!

[@ericvaught2111]

Okay, I tried to source your hacksaw blade with no avail... Correct me if I’m wrong but, it would seem that it’s not so much a blade as in flat but round? Still kinda “sand paper” cover just like the blade types are. Any help would be much appreciated, thanks.

[@sydfixesbikes]

It's a carbide cutting blade: amzn.to/3nc4zWL

[@tisforturbo.3774]

Love the Jamis Dakar 650 team bike was my fav until I upgraded to a pivot mach 4

[@baseljamal8907]

What direction did you lay the carbon fiber layers in? I mean, what was the orientation of the fibers and why?

[@lunam7249]

90 degrees, like a clock 3 hours, fibers are stronger in thier direction

[@anthonysteellarenas7367]

does it still hold if it gets wet again?

[@Chasingtrails]

Haha!

[@jfaust97]

Would this work on an aluminum frame as well? I'm not sure how bonded this patch kit actually bonds to the frame v/s bonding with itself to create a rigid "sleeve" over the broken tube??

[@sydfixesbikes]

I think if you had a clean break not at a weld it would probably work as a temporary fix. Not sure how it would do if the frame snapped at a weld, which is what usually happens with aluminum bikes in our experience.

[@miketandthebike]

Good video, this thing is pretty sturdy, I’ve made a down tube protector with it, best thing I could do

[@janstrecker]

Great video! This qas an eye opener! I never thought repairing a carbon frame is feasible!

[@aaron___6014]

It's super doable

[@Chasingtrails]

Yeah there's a carbon repair business in the UK as well. Does awesome work.

[@jmoore3854]

What did you do to break the chain stay like that.

[@keithgarn9038]

So I am assuming it can still be professionally repaired after using the emergency patch kit?

[@sydfixesbikes]

Yup!

[@infinityhike]

So guys, it seemed the carbon patch was adhering mostly to the sanded paint. Therefore the same patch could be applied to any bike with a paint job for purposes of getting out of the woods.

[@sydfixesbikes]

Haven't tried, so we can't guarantee it, but quite possible!

[@xrom2501]

I actually used that wrap on my handle bars after getting hit by a car. Got me 25 miles home.

[@justinsebastian2007]

Will a wee ride baby seat mount to this?

[@nachelia]

Are the wraps carbon? I couldn't find any explicit material online saying it was. It was just listed as "fiber with resin"

[@MonMalthias]

dynamix-cdn.s3.amazonaws.com/jbweldcom/jbweldcom_855685633.pdf If you look at the MSDS of the fibre fix tape, you'll find that it's glass fibre impregnated with epoxy. Looks like the catalyst is water activated instead of your standard A+B epoxy.

[@watchesnwheels]

Well… it’s pretty much the same as applying a cast in fractures! 3M makes a similar (if not the same) product called Scotchcast which is essentially a fiberglass weave embedded in water-activated resin. The steps needed to apply the wrap is essentially the same (as per casting a across a fracture). Gloves first - then dip in water, squeeze out excess water, wrap tightly distal to the crack, smooth out the surface of the wrap, wait for the wrap to dry out.

[@MajykOyster666]

Any update on that permanent repair ? Would be nice to see that. :)

[@sydfixesbikes]

It's been ridden for the last couple years by kids on the local highschool NICA team and been a great bike for them!

[@zap...]

@@sydfixesbikes You had mentioned that a permanent fix from a professional repair facility video would be forthcoming. This would be great to see. What carbon repair facility did you use?

[@sydfixesbikes]

We sent it to Broken Carbon (link in description) and they did a great job! Didn't end up doing a video about it, but it's been ridden by racers on the local highschool MTB team for two years now and is still going strong!

[@socratelegris]

Really enjoying your videos. Thanks for sharing these and Merry Christmas.

[@HighVybeTribe]

Whatever happened to the fiberglass bikes ?

[@hermandahlgrense]

Another person underestimating the dangers of working with hardened carbon fibre

[@jnygaarddk]

VERY very few planes are made from carbon fiber. Airbus 350 being the only airliner I know of. And a few bizz jet, like the old Beechcraft Starship and Horizon. But they do have a ton of composite material on them, but not much of that is carbon. More glas and kevlar.

[@quesnoy1]

The only problem with this experiment is that, in sawing the carbon, you create a gap between the two halves rather than just a crack that can fit back together like a puzzle peace. That means the repair kit is being asked to, not just hold two puzzle peaces together, but to create a small structural peace to bridge the gap between two peaces that no longer have matching surfaces. That's a big ask.

[@bikingwithemily1109]

I've been waiting for this video since I saw it in the intro, a absolutely life saver on a super long bike packing trip. And in a way your right, sometimes you need to brake it more 😃 As a fiberglass repair and finish painter I've done it " screw it , I'm just gonna cut it out and rebuild it 🤣🤣"

[@timquain5341]

I cracked my head tube on my carbon Kona Process. Do think a professional repair will be as strong as the original?

[@sydfixesbikes]

Yup, good carbon repair people (like our friend Brady at www.brokencarbon.com/) will fix it back to the original strength!

[@southin5g]

Hello do you have used bicycle frames for sale trek Madone SLR Gen 7 size 50

[@FrankyDesign]

I'm happy with my MTB aluminum frame. It's harder to repair but less likely to break.

[@1975normal]

You just need to find a local welder to weld aluminum. Not that complicated.

[@nissemeys4766]

Wow that's surprisingly sturdy

[@bonneharkema2458]

I bet you can do this with ammunimamalinium frames as well. ;)

[@davidmessem]

I was thinking the same thing. Please try it Sid!

[@GHinWI]

Problem with that is a metal frame would typically break next to a weld, not in the middle of a nice smooth section of tube

[@davidmessem]

@@GHinWI good point. I have seen some cracks in the middle of tubes though

[@Zee-hl5iu]

@@GHinWI mine did..but it was cause i crashed on a rock haha

[@rantanplan7474]

absolutely love this channel!!

[@YellowfinCoachMatt]

why did you saw the frame?

[@marioman2471]

Lmao I’ve looked everywhere for a video of the sound of flicking a broken frame and have determined I am just paranoid, thanks lmao

[@BillSmithPerson]

That’s super impressive.

[@Icehso140]

Question for the intermediate rider. Which would have a tendency to break easier...Carbon fiber or aluminum? Good video.

[@sydfixesbikes]

Neither, really, as bikes are extremely well made nowadays. That being said, carbon is generally stronger overall (there are some interesting videos on KZbin of stress testing carbon to failure) but doesn't deal well with point specific impacts (like landing on a rock).

[@Icehso140]

@@sydfixesbikes Thank you. That's good to know. A lot of us may be able to afford CF but need more info to decide on future purchases. I am in the 60+ catagory so I doubt I'll be stressing any frames to their max anyway. I'm riding Orbea now with an aluminum frame, but may be going to a 29 hardtail just because I have room in the garage for it. LOL

[@sydfixesbikes]

N+1 for sure!

[@guskrassevich6373]

You guys are great! Thank you!

[@perryirons1399]

Good to know in case I break one of my carbon frames. Thanks!

[@NDemanuele1]

I had a crack on my downtube on my previous bike. Initially I thought it was the clear coat. In some cases its hard to tell. Anyway, I got it repaired.

[@sydfixesbikes]

Nice! Been working well for you since?

[@NDemanuele1]

@@sydfixesbikes I sold it to my Bro, so far he hasn't complained!...LOL.

[@bca-biciclindcuaxel7527]

You need to pull that harder !!

[@LaurentiusTriarius]

One thing that always scared me since I saw a dude broke a carbon hockey stick is getting impaled by all the shards from the frame in case of failure...

[@Sachiel235]

Heads up that kind of mask is made to filter the air going out, not so much in. Any carbon you inhale will live in your lungs forever. I always use a respirator when sanding anything like fiberglass or paint. The 3m masks with snap on filters are nice, but even an n95 that makes a seal around your nose and mouth will do the trick for most sanding purposes. Stay safe!

[@1975normal]

Great video- I think it would be strong 💪🏼 even with that carbon fiber tape. It just wouldn’t look as nice

[@iberiksoderblom]

My sailboat is for a great part carbon fiber. When ever it's out of water something allways needs some repair (or reinforcement). It's not that different from working with fiberglass.

[@matt7775]

There is absolutely no difference

[@alf3071]

what happens? do you always hit rocks with it or what?

[@michaelhorner4011]

If you're out of water on the trail....I wonder if pee would work :)

[@bluefire2505]

Can you please make a video about a permanent repair ??

[@jomaquiopatokong8328]

It's look like just a chain protector. But i think you can wrap it without sawing it. Just sand it and wrap. No need to saw.

[@keirfarnum6811]

That would get you home. Nice!

[@razmtb5028]

Awesome info!!

[@whiskeydelta4073]

Guys i don't know what to do. My polish (from Poland) carbon bike frame broke at the chainstay. I sent it to a company similar to Broken Carbon so i'm not worried about the chainstay breaking anymore (even if it breaks they will fix it again because it has warranty), but I don't have any more trust in that frame and i'm worried that it can brake in some other place. On the other hand it will be quite expensive to buy a new frame because this bike i have bought on a very good discount and i feel bike parts have gone up in price in general due to covid here in Poland at least.

[@sydfixesbikes]

Unless it's a really old frame, it's unlikely to break again as generally breaks are due to an impact or a weakness in one area of a frame (which you already found and had repaired).

[@FantasticPyroclastic]

did it HVRT? :D

[@paullmight42]

you need a mask while sanding too...unless you're wet sanding...be safe! really cool kit tho...and it clearly worked...!

[@Chasingtrails]

that was only paint - but yeah, better safe than sorry.

[@paullmight42]

@@Chasingtrails paint can be worse...

[@Chasingtrails]

@@paullmight42 normal paint isn't carcinogenic, whereas carbon dust is. Not good to breathe in any dust though. If you're spray painting that can be really bad without the right gear.

[@polishguywithhardtospellna8227]

6:54 This guy farted while his acetylene cutter was on, true story

[@South_Van_Ilse_MTB]

Super cool!

[@sorenoneil3876]

My friend had that done and the bike rebroke a few months later

[@luciejedlickova3361]

The bike is solid and my Ebike conversion went great. kzbin.infoUgkxHL1v1R3NE5x4KiYfyt8dnQmyNYz7qi5L Very smooth ride at 30mph with no problems (135 miles ridden so far). The picture is a bit deceiving - there is WAY less space in the center of the frame than it shows. The suspension connection takes up the entire thing. So I needed to attach my battery on the bottom of the frame and my controller on the top. Instructions for assembly were lacking but honestly it wasn't too hard to figure out even though I have very little bike knowledge. Watched some youtube videos on adjusting the disk brakes but that was it. Still, I am loving it and very happy with the purchase.

[@timothy24287]

Small, 48-50 cm.

[@jozefemperor]

I really don't understand why did you cut the frame with the saw? Couldn't you just wrap it over the crack?

[@zepp3lin]

It's for the show and showing us how strong the carbon repair job can be. A real situation I will not cut it.

[@sydfixesbikes]

Sorry if that wasn't clear! Macky had ridden the bike for awhile before noticing the original crack so it might have survived all our tests anyway and we would have gotten 100 comments saying "that won't work if it's really broken" etc. We had to make sure it was all the way broken for the sake of our experiment (and our own entertainment tbh 😂)

[@kleini3]

Tap test ist pretty useless with carbon frames since the thickness of the layers can change on multiple places on something like the top tube so the sound changes even if everything is fine

[@David-xl9cp]

Shouldn’t have cut the frame with a wrap as this will further weaken the joint :-) But go for it Syd, girl on a mission, good for you

[@paulb9769]

That is what I thought to. Sanding and wrapping would have been enough.

[@richardjones2811]

I think if there's a business out there totally aimed at fixing broken carbon frames then carbon frames should be questioned!

[@tychoMX]

nah. All bikes can break. Steel, Al, Titanium. Although to be honest I've never seen a Mg frame, I'm sure they break too. Repairing a run-of-the mill steel frame is almost trivial for anyone with welding experience. TIG repairs for titanium, not as much. And aluminium tends to be a bit more problematic because you probably need to heat treat it to make sure the alloy hasn't unreasonably weakened.

[@bioshift1]

You need to put water on the carbon while you cut and or sand. Very dangerous to do that dry. Or at least have a extraction fan to get the dust away from the work area.

[@criticalthought7527]

I'm worried that a fan might make things worse. I use wet paper towels when cutting steerer tubes, but will try the soapy water next time. Maybe both.

[@bioshift1]

@@criticalthought7527 I used the wrong word. I mean like a fume extractor. Kinda like people use for welding and soldering.

[@criticalthought7527]

@@bioshift1 , Sorry, I read your comment too quickly to pick up on your meaning. Great idea for the pros, but there is no way I could justify the expense for our shop. The wet paper towels and an N95 seemed to work OK, especially for controlling the falling dust. But I'm hopeful that the soapy water will be even better. I don't need carbonosis of the lungs. ;-) Be well, j

[@bioshift1]

@@criticalthought7527 Yup no problem, Totally understandable man. Be safe and have a good holiday.

[@tomgdownhill]

The carbonfiber repair business owner was way off when talking about aluminium repair 😅 and when i fixed carbon frames, i sold them very cheap with a big heads-up warning ⚠️ not really something to giveaway and have an unknown rider, and have an accident due to the repair. Never as good as the original full length of strands.

[@AndrewBlucher]

Wow. Great!

[@thomaszabukosek979]

Apparently squeezing a damaged frame is a great way to increase the damage. So maybe remove that bit? Otherwise love your videos!

[@hasdas9088]

That stuff reminded me of velcro...

[@Tubbs_1971]

Next time get a mask with a respirator. Thats not a particle mask you are wearing. Better than nothing but youd have been better off with a bandana than that little mask. I wonder if you can use carbon patch on an aluminum frame. Would it adhere to it?

[@rfwillett2424]

It would probably work for a while as an emergency repair, the better the preparation the longer it will last. With proper preparation of the aluminum, and if you used the correct primer for the resin, it would be permanent. The Australian Air Force has used composites to repair airframes for decades.

[@Tubbs_1971]

@@rfwillett2424 thanks. I hope i never crack my frame. Its a trek so its covered but this is nice on trail fix.

[@sydfixesbikes]

I imagine it would work if you got a clean break. In our experience aluminum frames often bend before they break tho. Or break along a weld 🤷‍♀️

[@mattgies]

This may answer your question--an ad for the product in question where they sawed a steel BMX frame in half and then taped it back together with the product: kzbin.info/www/bejne/o6O6eYd-hat0pLM

[@jeremynorth]

You should have sanded down the chain stay before cutting it.

[@trailhobbit9103]

Add a "Lizard Skin" (or similar) chain stay protector ... and nobody knows!

[@jackiegammon2065]

There are definitely many companies out there that repair carbon fiber frames, nothing new here. Although I think most folks realize that it is NOT a long term fix, I also know as a shop owner how many times someone thinks there is nothing wrong with a bike...when there actually is. So I think it's wise to show what is out there for info/products, but wonder whether some will think that is a long term fix if they ride only a few times a year. I love the info, but also wonder if this is a slippery slope to get into....

[@nolocbx1]

Congratulations Syd. You now have carbon fiber in your lungs. They’re permanent and the mask you used does not protect you from those microscopic shards of carbon fiber in the air. I’m sure Macky wasn’t wearing one either. N95 or better.

[@solitaryrefinement6787]

I'm just here for all the "duct tape" comments. 😎 Also, it's cheaper to just buy an all new aluminum frame than to repair it and it takes a hell of a whole lot more to cause aluminum to fail than carbon. In fact, you can get a whole new comparable aluminum bike for the cost of a carbon frameset. BTW, the repair kit is a great idea and now there's a permanent chainstay protector on it. 👍

[@thim8009]

I was looking into everything I can after watching this and everyone sanded down past white layer to carbon mesh.

[@sydfixesbikes]

I suspect those were people trying to do a more permanent repair. The idea behind this was something that would get you home if you cracked your frame on a big ride and then you'd send your frame in to a professional to have it repaired properly...

[@thim8009]

@@sydfixesbikes ya your right and thanks for showing. You can go for crash replacement but with covid you might have to wait a year for a frame.

[@jcsrst]

Hacksawing a frame is like nails on a black board 😱!

[@stevencole7331]

Remarkable

[@riensartwork]

nothing lasts as long as a provisional solution

[@thim8009]

Thats awesome

[@LorenzoTheFisherman]

approximation to its finest

[@paulb9769]

I do not understand why you cut it? I would have just sanded and wrapped it.

[@sydfixesbikes]

We wanted to show that this emergency repair would work for serious crack.

[@lolgabelol100]

The bond prep gave me cancer

[@TechnoUndergroundOfficial]

Magic Carbon

[@tolfiboyProduction]

A ffp1 mask is not effective at all against carbon dust :/

[@TheDuke-n7o]

Thats one of the reasons I don’t buy carbon bikes... crash happens and all it takes is a nice rock to crack it. I work with carbon fiber fan cowl doors after I build a turbofan engine and during steps and gaps I’ll have to remove some of the carbon and that dust gets everywhere and dust masks are required.

[@nerigarcia7116]

This hurt to watch but it was cool.

[@dtolios]

Cutting carbon = 😷. Sanding carbon? = eeh, we won't live forever 😀

[@Chasingtrails]

Sanding didn't go through the paint. But still...

[@dtolios]

@@Chasingtrails if we are splitting hair and counting molecules, the paint was dug out during the sawing, so...at least some was sanded on directly. And it's not like carbon particles are toxic while the paints/clearcoat or even aluminum etc are benign. If the mask is handy, use it for all these tasks.