Cannondale Braze-on Tab cracked/broken



Mike Geneva

New Member
Mar 4, 2013
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Just a quick post for those interested in replacing a riveted braze-on tab. My Cannondale Evo Supersix has a cracked/broken braze-on tab. I took it in to a Cannondale dealer this week to get advice and was thankfully told they had a replacement part available and they would send it to the dealer for in-house repair. I intend to report back on the success of the operation hopefully by week's end. The tab will have to be riveted on. The head mechanic seemed like a nice guy and confident he could do it. I checked out some youtubes myself dealing with composite materials and metal skeletons on aircraft and it would seem this is fairly common in aerospace. I'm very interested in the aluminium rivet that they'll use. I had another bike dealer suggest to me the real key was the backing inside the tube itself. I was told that Giant's top-end bikes have a plate that is a b*tch to put in when doing this repair. I have no idea if Cannondale uses something like this, though the mechanic told me they have to take out the bottom bracket. I also caught a bit about epoxy, so I'm guessing that there's some kind of epoxy bond between the braze tab and the frame . . . maybe that's the key to the strength around the holes in the frame?

Has anyone else had this problem?
 
this braze-on is a combination of carbon and aluminium ? the replacement part should be aluminium that can be reinstalled ? i guess it works like the aluminium or steel dropouts on a carbon frame, if they are damaged it is easy to reinstall a new one,
 
It's all metal - either high tensile steel or titanium. It's riveted into the carbon using aluminium pop rivets The trick is removing the existing rivets and then using the correct type of pop rivet. Cannondale supplier originally told the shop they were sending the part right over. Then they decided that it wasn't covered under warranty so they took no action until we chased them. It's 50 buck kit and for some reason they thought I might not want to go ahead with the repair on a 10 grand bike! Jeez - go figure?
 
Mike, was the repair made successfully? Believe the design with the aluminum rivets is intended to have them shear off in case of overload rather than risking frame damage. The backing plate is of course used to prevent the rivet heads pulling through the soft CF seat tube by distributing the load. I'm guessing they use epoxy to secure the backing plate only. Bonding on the FD bracket, or using stronger rivets, would defeat the "fail-safe" design.
 
Hello mike, I hope your lbs was able reinstall the tab. It would be nice to hear, making me feel a bit better. I say so because I have the same issue going on. My front tab for the der. is cracked on my Cannondale Evo. I was thinking about replacing it my self If I'm able to buy the replacement part. I'm a mechanic my self but my shop is not a cannondale dealer. A shop here in Chicago might be able to get the part for me.

hopefully we get thru this quick..

keep me updated on your half!
 
Hello mike, I hope your lbs was able reinstall the tab. It would be nice to hear, making me feel a bit better. I say so because I have the same issue going on. My front tab for the der. is cracked on my Cannondale Evo. I was thinking about replacing it my self If I'm able to buy the replacement part. I'm a mechanic my self but my shop is not a cannondale dealer. A shop here in Chicago might be able to get the part for me.

hopefully we get thru this quick..

keep me updated on your half!
 
Hi,

Just dropped my bike off with the same issue, cracked braze on. Dealer told me this was a know issue and is covered under warranty. Dealer said they made the braze on metal too thin. The bike needed to be disassembled and sent back to Cannondale so that it could be placed in a jig and repaired with a heavier braze on. Not going to get the bike back for a month at minimum. #cannondale #brazeon #warranty #repair

Caffrey
 
My braze-on tab was fixed by a Cannondale dealer in Sydney.

Cannondale manufacture a replacement kit for this very purpose. The Cannondale dealer I used was a little vague on the fix. Maybe at the time they were just covering their behind in case they had an epic fail. The kit was about 50 bucks. I paid a couple of hundred including a tune-up and some bits and pieces. Cannondale Australia took a week to get the kit to the dealer even though it was in-stock and in my city etc. Apparently as I had bought my Evo while living in Switzerland they had decided not to cover the frame under warranty and didn't know whether I wanted to go ahead with the fix. So they waited until I returned to the bike shop before getting another confirm that I was happy to go ahead. A bit frustrating. Who throws away a 4k frame for the sake of a 50 buck kit just because the manufacturer decides they won't cover it?

When I got the bike back I heard some rattling. The mechanics had drilled out the pop-rivets and left the back side stubs in the frame. Just sloppy. After a couple of rides I took the bike to an independent shop who OK'd the job (he's done this before on various brands . . .said Giant was the hardest job because of some interior plate?), but had to retune the bike for me.

The back end of the story is that I cracked the frame on the same bike when some road debris got got in my rear derailleur and caused a catastrophic failure. The derailleur detached and hit the frame under full load going up a hill and cracked the carbon.



I replaced the frame via Bike24 in Germany after Cannondale Australia were unwilling to order-in what I wanted. They did offer me a 20% discount on a choice of two frames from 2012 - appreciated, but as I said to them . . . happy to pay full price and get what I want. Instead Bike24 gave me what I wanted and a big end of 2013 discount. I had an alternative Cannondale dealer (Cheeky Monkey Sydney) set it up and they've done a great job since in servicing all my bikes. Just good guys to deal with.

I love my Evo and am problem free now. I will have the old frame repaired by a carbon specialist here in Australia who assures me that this is a very straight forward job. He's quoted $500.