The threaded boss (see pic 1) dislodged and fell into the aluminum frame (see pic 2). I was removing the bike rack, as I've done before, to transfer to another bike. I want to be able to mount a rack on this frame, what would be the best way to repair/replace this?
My LBS tends towards jerryrigging, so they didn't have much of an idea—especially with the difficulties of aluminum welding. They said something about trying to get a nut in there—someone even suggested drilling to the other side and running a bolt all the way through. I called the original bike shop to see if Giant's frame warranty would apply (it's lifetime, the bike is 3 years old), but they think it's unlikely.
by hmph_
4 Comments
try getting a same size rivet nut perhaps? make sure it receives the same size bolt as on the other side.
I would want that hole plugged before riding, it’s probably weaker now than before.
I would look into epoxies designed for metal bonding, they can rival welding. If you go that route, be sure to keep the layer of epoxy between the metal surfaces thin.
Here is a repair I made on an aluminum frame: https://www.reddit.com/r/BikeMechanics/comments/1shs098/repair_of_a_broken_aluminum_frame/
Options:
Aluminum welding -quick tig job.
Brazing – more accessible than TIG, can do in your garage.
JB weld
Listed in order of descending order of strength.
I wouldn’t bother with trying to replace it, or repair to the hole. “Make it worse” 100% likely. Put a p-clamp there and go.