2005 Trek Top Fuel 110 Team Issue - Repair and Restomod

[Mikey08]

Now for the more nerve racking stuff....

I cleaned up inside the headtube and re glued the lower insert. Used a DIY headset press to hold it in place.





Then I started preparing some carbon to reinforce the frame for a dropper post cable port.....

8 layers of carbon prepared in alternating weave directions..




All in place and wetted out..




Wrapped in shrink tape. It has a release agent so it's easy to remove.



Also did the patches on the seat stays.





Next up is to feather in and smooth the carbon patches and make the hole for the grommet.

Then onto painting and decals

 

[Mikey08]

Getting there....






Special thanks to MrDickens who did a wicked job sanding the back end. 3 rounds of sanding with 220, 400, and 800 grit paper got my rear end silky smooth.





Also modified the cable stops as I won't be running a front mech

 

[Mikey08]

Well this was labour intensive

 

[Mikey08]

 

[Mikey08]

Today's graft....








Dont be a twat like me, **wear gloves and a mask when working with carbon**. I rigged up a bit of extraction so don't worry. I should survive long enough to finnish this

 

[Mikey08]

Small update:

I wasn't happy with the cable guide arrangement on the frame. The guides had a older style system for the rear brake hose that was a bit janky and offered no support for the middle of the brake hose. I want the bike to be as quiet and rattle free as possible. Also wanted to change from a interrupted shifter cable to a full length housing set up because it looks better and keeps the crap out.

So I removed the guides from the top tube and drive side seat stay and have spent the last couple of days working on consolidating those areas with fresh carbon ready for the new guides to be glued on.

The top tube guides came off clean but the seat stay cable stops were a different story!. When I removed them quite a bit of carbon came off too. I've had to grind out the damaged area and add 6 layers of fresh carbon. Been a right pain in the backside lol but were learning on the job

The new guides have had to be ordered from the US so it might be a while until I can continue.

I have all my paint ready. 2k Epoxy primer, 2k clear gloss, 2k clear Satin, and metallic black base colour. I just need to order masking decals for the down tube and a head tube badge.

Photos!




.

 

[Mikey08]

I've also customised my shock a bit.

Too much?

 

[Mikey08]

...and planning to get this head tube badge...

 

[wadsy]

Good stuff

 

[Mikey08]

Almost forgot, I have a new CNC mech hangar and bolt from Race Ti