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Marshy
10-07-2013, 12:43 PM
One of my bikes recently had a small accident and broke a steering stop - a very common occurrence on racebikes! Here's how to fix one. It's not very time-consuming once the triples are out of the steering head.

The problem:

http://tarmactalk.com/forum/images/uploads/stoprepair-1.jpg



Support the bike so that you can remove the lower triple clamps - obviously a headlift stand isn't gonna work ;)

http://tarmactalk.com/forum/images/uploads/stoprepair-3.jpg



Undo the steering head nut

http://tarmactalk.com/forum/images/uploads/stoprepair-2.jpg



Clamp securely

http://tarmactalk.com/forum/images/uploads/stoprepair-4.jpg



Drill a 5 or 5.5mm hole. No need to go all the way through! Use a shorter bolt, or trim the bolt down

http://tarmactalk.com/forum/images/uploads/stoprepair-5.jpg



Tap a 6mm thread

http://tarmactalk.com/forum/images/uploads/stoprepair-6.jpg

http://tarmactalk.com/forum/images/uploads/stoprepair-7.jpg



Insert a 6mm bolt. It important to get the height slightly lower (couple of mm) than the OEM steering stop. Mine is a couple of mm higher than optimal, but is close enough for government work. Check it against the other side

http://tarmactalk.com/forum/images/uploads/stoprepair-8.jpg

http://tarmactalk.com/forum/images/uploads/stoprepair-9.jpg



Get some of this magic liquid metal stuff!! Cheap from Bunnings etc, and very easy to work with.

http://tarmactalk.com/forum/images/uploads/stoprepair-10.jpg



Knead the epoxy and shape it into a new stop, over the bolt.

http://tarmactalk.com/forum/images/uploads/stoprepair-12.jpg



Admire your work for 10 minutes while the epoxy sets! (It'll be rock solid in under an hour, but is solid enough to put back in the bike after 10 or 15 mins)

http://tarmactalk.com/forum/images/uploads/stoprepair-11.jpg

http://tarmactalk.com/forum/images/uploads/stoprepair-13.jpg

http://tarmactalk.com/forum/images/uploads/stoprepair-14.jpg



Reinstall, and check that it clears the frame! If it's too high, it'll catch.....

http://tarmactalk.com/forum/images/uploads/stoprepair-15.jpg



Handyman would've spray-painted it silver, and then you'd never know it was a repair! I didn't have any (and it's a racebike, so who cares, right?) so I just left it looking ugly but fully functional.

Baddie
10-07-2013, 01:49 PM
:rockon:...Good job.

Negrogrande
10-07-2013, 02:50 PM
well done!

dan
14-07-2013, 07:40 PM
Very clever

Team Zero
14-07-2013, 08:37 PM
Nice work. But you know it would have taken me 2 weeks while I cleaned everything.

chubb
14-07-2013, 08:52 PM
Interesting

Condor
18-07-2013, 08:48 PM
Marshy I had already done mine before seeing this and drilled the whole way through! Oops, You think i should fill er in with that metal knead stuff and go again??

Cheers Mate

Little Mick
18-07-2013, 09:49 PM
through is not a prob as long as you have a thread in there and its deep enough for hold the bolt... once the knead it cures the bolt wont go anywhere... use a longer bolt to get more engagement - it will be betterererer.... if you are worried, you can always add a lock nut to the arrangement before applying the knead it...

Marshy
18-07-2013, 10:34 PM
I'd actually recommend still using a short bolt, and then bunging some of the epoxy in the bottom of the hole from underneath once the bolt is in. In another accident, you still want the bolt to be the weakest part - better to rip the bolt out than snap the whole bottom triple in half.

Little Mick
19-07-2013, 05:33 AM
To be honest Marshy- the Allen head bolts are generally high grade- 8.8/ 10.9 or 12.9 The bolt is unlikely to break but may bend. As for snapping the tree, can see that happening in a hurry.. keeping in mind the the section in the tree would remain static and the bend would take place at the shear point - top of the tree materia...then again...its a steering stop...not tested until its tested....
as a minimum I would personnal go for 15-20mm of embedment..

Edit-- I just reread your post Marshy - You did indicate pull out not that it would break...

Condor
19-07-2013, 03:41 PM
Awesome Lads, Thanks for the info.