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Carbon Wheel Repair
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JaRok2300




Joined: 01 May 2014
Posts: 332
Location: Worcester, UK

PostPosted: Wed Mar 21, 2018 2:44 pm    Post subject: Carbon Wheel Repair Reply with quote

I picked up a cheap disc wheel on a bit of a whim and looking for some advice on a repair if anyone has any experience.

It's an old HED which I'd (wrongly) assumed was a spoked wheel with a carbon skin as I though that was all they made. It appears to be a structural carbon disc as there are no sign of any spokes through the valve cut-out (although there are spoke holes in the alloy rim)

I knew it had a small hole in the skin when I bought it but it was cheap enough to take a punt and I'm going to try and fix it using a carbon repair kit with resin and cloth patches.

My main question is what to do about the hole which is about 1cm round but still has the flap remaining that has broken. I'm not sure whether to fill it with as much resin as possible then patch over it or whether I should grind it out to a perfect circle to remove any stress risers first and then patch over the hole.

That and any other advice gratefully received.

Ps. I don't really want to send it off to be repaired as I think the cost would make it better to just cut my losses. Especially as I've just scored a pair of HED tri-spokes, drinking and e-bay are not a good combination.
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JaRok2300




Joined: 01 May 2014
Posts: 332
Location: Worcester, UK

PostPosted: Wed Mar 21, 2018 3:08 pm    Post subject: Reply with quote

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Chrace




Joined: 28 Apr 2010
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Location: Eating a Yorkie

PostPosted: Wed Mar 21, 2018 3:53 pm    Post subject: Reply with quote

I thought they were spoked as well. Low spoke count so you simply just can't see them at the valve hole?

Nowhere near a specialist, and since it's a wheel you'll probably want one, but a small dent like that in a large "solid" surface seems fairly solid to me? Just tape it over and you'll be reet. Wink
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JaRok2300




Joined: 01 May 2014
Posts: 332
Location: Worcester, UK

PostPosted: Wed Mar 21, 2018 4:13 pm    Post subject: Reply with quote

No, it's definitely got no spokes. Just had a brainwave and used the light off by Brompton to shine inside and can see all the way down to the hub.

It's a Pro-Am which must date to before HED started using the spoked construction.

I'm thinking that the valve cut-out is about 10x the size of this hole (and on both sides) and doesn't appear to have any additional reinforcement so as long as it doesn't propagate further and develop into extended splits it shouldn't have much affect on the strength.
On the basis above I'm leaning towards cleaning the hole out to make it more uniform before patching it.
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blindcider




Joined: 12 Sep 2013
Posts: 258

PostPosted: Thu Mar 22, 2018 11:54 am    Post subject: Reply with quote

This slowtwitch thread might be helpful in your case: http://forum.slowtwitch.com/forum/Slowtwitch_Forums_C1/Triathlon_Forum_F1/Damaged_my_Sub_9_disc_-_any_advice_P3478003/
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JeffB




Joined: 04 May 2008
Posts: 1178
Location: Middlesbrough

PostPosted: Thu Mar 22, 2018 8:13 pm    Post subject: Reply with quote

You could look up Fibrelyte who do excellent repairs to carbon frames but given they are at the opposite end of the country postage might be an issue.

Jeff
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Chrace




Joined: 28 Apr 2010
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Location: Eating a Yorkie

PostPosted: Fri Mar 23, 2018 8:45 am    Post subject: Reply with quote

JeffB wrote:
You could look up Fibrelyte who do excellent repairs to carbon frames but given they are at the opposite end of the country postage might be an issue.

Jeff

I used carbonbikerepair via post before and can recommend them. Found a crack in an eBay MTB frameset I had bought (and obviously not inspected well enough when I picked it up) and they did a good job.

But as you say, wheel might not be worth it.
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JaRok2300




Joined: 01 May 2014
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Location: Worcester, UK

PostPosted: Fri Mar 23, 2018 9:25 am    Post subject: Reply with quote

I found some huge pdf on-line yesterday setting out industry standards for repairs to carbon that goes into quite a lot of detail about different types of repair and the pros/cons.

It was very clear on removing any broken fibre and making sure the hole was round or any corners had as big a radius as possible. I got a repair kit with the right resin and some weave so I'm going to give it a whirl myself.

What could possibly go wrong?

Ps. At least I know where to find plenty of dentists for follow up advice in a few weeks time!
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Chrace




Joined: 28 Apr 2010
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Location: Eating a Yorkie

PostPosted: Fri Mar 23, 2018 9:49 am    Post subject: Reply with quote

You so have to report back on this one. In writing, so no teeth required to speak. Smile

Can't wait to see the result.
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explorerJC




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PostPosted: Fri Mar 23, 2018 9:54 am    Post subject: Reply with quote

i would be very nervous of a carbon wheel repair....the risk is just too high...
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JaRok2300




Joined: 01 May 2014
Posts: 332
Location: Worcester, UK

PostPosted: Fri Mar 23, 2018 10:47 am    Post subject: Reply with quote

I have concerns too, would be more so if it was the front.

I'm basing my optimism on:

It's a very small area of damage, a 10mm hole will completely remove it.
It's pretty much in the middle of the skin so if it started spreading I would see it before it got anywhere near the rim or hub.
The cut-outs for the valve are bout 10x bigger and have no visible reinforcement.
The carbon is really thick, much thicker than newer wheels I've seen so suspect it was over engineered in the beginning.
It's got an alloy brake track so there is some inherent strength in the rim too.

Of course all of that may prove to be nonsense if it catastrophically fails without warning but I was never very good looking to begin with. Sad
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explorerJC




Joined: 20 Oct 2005
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Location: Farthingstone

PostPosted: Fri Mar 23, 2018 12:15 pm    Post subject: Reply with quote

JaRok2300 wrote:
I have concerns too, would be more so if it was the front.

I'm basing my optimism on:

It's a very small area of damage, a 10mm hole will completely remove it.
It's pretty much in the middle of the skin so if it started spreading I would see it before it got anywhere near the rim or hub.
The cut-outs for the valve are bout 10x bigger and have no visible reinforcement.
The carbon is really thick, much thicker than newer wheels I've seen so suspect it was over engineered in the beginning.
It's got an alloy brake track so there is some inherent strength in the rim too.

Of course all of that may prove to be nonsense if it catastrophically fails without warning but I was never very good looking to begin with. Sad


wear chin protection!!!!

I am not an engineer, but I understand that the layering of carbon is designed to spread the load evenly.... according to the direction of stress....

That said, a good mate of mine tried to drive into his garage with his Ceepo on the roof rack....the bars spun into the top tube puncturing the carbon....he taped over the 3 x 2 cm hole and raced it without drama for several months more...
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JaRok2300




Joined: 01 May 2014
Posts: 332
Location: Worcester, UK

PostPosted: Fri Mar 23, 2018 12:27 pm    Post subject: Reply with quote

Just read the instructions on the carbon repair resin. 21-25 degrees C and well ventilated. It may be a while before the shed meets those criteria and the chances of the Mrs allowing me in the house with something producing noxious fumes are no hope and Bob Hope, and Bob's dead.

Anyway, picked up my new toys last night so have something to keep me occupied until I get round to the disc. I'll try and post a picture from my phone below.


Last edited by JaRok2300 on Fri Mar 23, 2018 12:39 pm; edited 1 time in total
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JaRok2300




Joined: 01 May 2014
Posts: 332
Location: Worcester, UK

PostPosted: Fri Mar 23, 2018 12:38 pm    Post subject: Reply with quote

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Mungo




Joined: 29 Sep 2016
Posts: 377
Location: Preston

PostPosted: Fri Mar 23, 2018 12:48 pm    Post subject: Reply with quote

HQ carbon repair Norfolk.
Mended my zipp 303 tub so well that when it came back I couldn't find were it had been mended?!
But it had a small crack when I sent it so hey ho.

Not so lucky with my Xentis mk1 tt front... they said it couldn't be mended safely so some integrity too.
Great feed back and quite cheap too.
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