Aaron,
It wasn’t that big a job. I think it took one weekend, or two 6hr days. You need the right tools for the job however. A drill-press, cobalt-steel bits, and a cutoff saw. If you have none of these tools, $500 will pay for them. Somebody else had something similar fabricated, but I can’t remember who. Perhaps he could let us know the cost and effort required to do it that way. After fixing the chainplate as described, there is absolutely no sign of stress. The steel brace behind the plate might be overkill. Aluminum might be easier to work and yet strong enough in this application. If you went with aluminum, you could probably cut the pieces yourself using a sawsall. I think you’d still need a drill-press, but generic steel bits would cut the holes. You could send the chainplate out to a shop to have it cut and drilled. I went with steel because I already failed to fix the problem once. I hate it when I think I fixed something only to find that my repair was inad
equate
.
I think I should have sent the chainplate out for electro-polishing after I finished fabricating it. There some sign of minor corrosion.
—
Rich Carter
Original message
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