here, here, here
here
here

We often get asked about doing internal Di2/EPS conversions to frames that were not originally designed with this in mind.

Can I just drill a few holes where I want the cables to come out?

Drilling holes in a frame is NOT recommended, be it carbon, aluminium, steel or titanium.

 

Performance bicycle frames have been engineered in the factory to have minimum weight for the loads placed upon them. Drilling a hole removes material needed to carry the loads and also acts a stress concentration.

A factory ready electronic shifting frame has had analysis done on the structural implications of the holes and extra material placed around the area to distribute the loads. The location of each hole and the structural design is carefully considered to ensure it is safe.

 

Without this analysis the frame is NOT safe to ride.

 

The image above is an extract from the Kenworth truck manual. As you can see they have very clear guidelines for drilling holes in the chassis. They are rightly concerned about the structural implications of drilling holes in 10mm thick steel beams.

 

Drilling holes in the frame will also void your factory warranty and also may have legal implications if it fails and people get hurt. Yes we are conservative, all those years working with aircraft we used to say “nobody wants a plane to fall out of the sky”. The same way I don’t want to see people get hurt while out enjoying riding their bikes.

 

The battery also needs to be considered, Lithium batteries without the correct protection circuit are prone to fire if incorrectly handled, you definitely do not want an internal fire in the seat tube of your carbon frame. This issue actually recently grounded the Boeing 787 fleet

We always recommend using a frame and parts designed and tested for the purpose intended.

 

Safe riding.

 

Here is an article that was published by MTBA Magazine about carbon repair on mountain bikes.

John Hardwick (the Editor at MTBA) came to our workshop and documented a typical repair, on his own Scott Spark which suffered top tube damage.

The article in pdf format can be found here (1.1Mb)

Here is a video showing a close up view of what carbon really is.

 

We often get asked if we repair carbon wheels.

 

Well the answer is yes, the typical repair cost is around $240, it just makes sense.

 

 

You would get a used car inspected before you buy, you get a builder to check the house you want to buy, so you should also get your carbon bike professionally assessed. Not only is there a risk of losing money but the bigger risk of getting injured due to a structural failure.

 

Because carbon is different to metals in the way it can get damaged, it can be difficult to know if the part is still structurally sound. Unlike metals where a visual inspection should find cracks and dents, delamination damage can be invisible on the surface because it is within the layers of material that make up the structure. A delamination in a thin carbon laminate can have a catastrophic effect on the strength of the part.

 

 
Ultrasound scans are proven to find this damage which is why it's used in aerospace to certify aircraft safe to fly.

 

At Luescher Teknik we use our extensive experience with carbon bikes AND over 25 years Ultrasound scanning experience to give you the rider peace of mind that the bike you buy does not have any hidden damage that may cause problems.

Our assessment process can find damage and manufacturing faults that even the factory can't find to give you the ultimate peace of mind. For more information on the assessment process and service fees click on the "Bike  Inspection" tab in the menu.

 

We have also been doing these assessments for our customers looking at selling their bike to be sure that they don't pass on a bike that could cause an injury, in a similar way a "Roadworthy" is required when selling a car. With our report they also are more likely to get the true value price when they sell.