Anyone used Durafix Easyweld to repair an aluminium frame?

Jond is right, Inserting a rod of any material down that will make no difference to the strength of it whatsoever, the insert still wont be attached to the frame with anything stronger than the bond you get, and it wont be enough.

The rod inserted inside a frame tube works fine but its usually pinned in a few places either side of the break, so you have the insert wleded in, the frame crack welded to the insert and itself and the pins welded in, stronger than it was before it broke.

ADH's sugestion is the best your likely to get, but maybe you could just leave the mast in place so it looks right, it wont make it any stronger to remove it.

I have no direct experience of the product you have in mind, but quite a few car companies bond alluminium chassis together Lotus/Aston, the thing they have that you dont is a substantial area of contact to glue.

Mattsccm, sounds like a plan… that's the sort of 'cheap yet functional' method I was hoping to employ (though using this Durafix product for the crack filling duties…)

cheers again for all the advice, keep it coming (if there's anything to add 🙂 )

It looks like there are many methods that 'might' work. Unfortunately you want one that 'will' work, and no-one will be able to guarantee that any particular method will be successful.

Good luck.

I'd try weld first, and if that din't work go for an insert.

Bonding with epoxy is perfectly strong. Get a clean joint with an insert and make sure no peeling force.

Any update on if any of this has worked?

I have tried a product very similar to Durafix to attempt to repair a crack in an aluminium bumper for a classic car. Even with lots of practice first the results were pretty poor. It was like kind of like soldering, but the area I was trying to fix was flat, I couldn't see your pictures but if the crack was where two tubes joined, then the Durafix might fill a bit better, but I wouldn't be convinced that it would be strong enough.

My friend fixed a carbon road frame that had a damaged seat tube, by bonding in an aluminium insert.

Great thread

I think the temperatures involved with durafix would be enough to effect the heat treatment

Have you got a quote for a proper repair, weld and heat treat if necessary. That will give you a basis for comparison

I took a demo Tracer out one day, lowered the seat post and managed to bend the clamp just tightening it! WTF if I can bend a seat post clamp………….

I know Intense bikes ride well but I have seen to many cracked frames to give them a go!

Any update on if any of this has worked?

Whoops… sorry, just saw your post 😳

Haven't actually moved on to repairing the frame, have in fact decided that I don't actually need it in all honesty, so it's now up for sale again (actually in the classifieds now if anyone's interested 🙂 )…