I managed to break the frame of my 1999 Kona Stinky this morning while riding in Thetford. It was my pride and joy. The top tube broke near the seat tube. It appears to be a clean break as there’s no oxidization on the exposed aluminium.

Question is: is this terminal, or can it be fixed (I have access to someone who could weld it)?

(PS if anyone has a ’99 or 2000 Stinky with a broken swingarm they want shot of…)

oh and terminal.

🙁

If your welding friend can weld the cracked top tube area 1st, plus weld a wrap around gusset around the seat tube and back over both sides of the re-welded top tube it might hold up. The trouble is the frame will have originally been heat treated in production, and re-heating during your welding repair may actually weaken it second time around.

I have seen this extra gusset approach done a few years back on my team mate’s downhill bike in the same place and it held up for another 18 months abuse before failing again at the new weld.

The alternative is to search ebay for a bargain mainframe to replace it?

Try one of the motorcycle frame fabrication places – Harris or the like. they have experience with welding thin alloy. Not going to be cheap or easy – and as suggested above will need to have extra material welded on. Not all alloys are / need heat treating

You need a specialist welder IMO

try and blag a warrenty repair!

Most repairs won’t be as strong as it was in the first place… So if you broke it once, it’ll break again. Sorry, but realistically a new frame makes more sense. A welder who knows his bikes could probably do you a reasonable repair but it’ll need refinished afterwards too.

We must also bear in mind that alu does fail eventually due to fatigue and you wont see any oxidation on it (alu oxidises near instantly in actual fact, its just colourless). A 10 year old DH frame is likely to have seen a lot of loading and fairly heavy use, I dont think its unreasonable to assume it may die at this age. Advice re welding/extra material above is sound, and as mentioned it’s likely to cost a lot if done properly – suspect a new frame may end up cheaper.

new frame, much safer

Thanx for your advice everyone.