Carbon Frame Repair

Most carbon frame damage looks worse than it has to be. A crack at the top tube, a crushed chainstay from a dropped chain, a crunched down tube from a rock strike, delamination around the bottom bracket shell — these are all repairable when the damage is addressed as a structural problem rather than a cosmetic one.

Our process starts with a full removal of the compromised laminate. Every ply that's cracked, delaminated, or otherwise no longer doing its job gets cut out — not sanded down or glossed over, but actually removed down to sound material. We then rebuild the area ply by ply, matching the fiber type, weight, and orientation of the surrounding laminate, and scarf each new layer into the existing frame in a tapered transition. That taper matters: dumping extra reinforcement onto a damaged area creates a stiff spot that concentrates stress at its edges, which is how a 'repaired' frame fails an inch away from the repair. A scarfed, layered connection carries load the way the original frame designer intended.

The layup is cured under even, external pressure using a silicone mold built to the tube's actual geometry. This is the detail that separates a durable repair from a cosmetic one: vacuum-bag lamination pulls a single layer of plastic film down over the wet laminate, which tends to trap air and telegraph wrinkles into the cured part — wrinkles that become stress risers exactly where you don't want them. External-pressure molding instead squeezes the laminate uniformly from every side while direct heat drops the resin's viscosity, so the fibers stay straight and the resin flows and consolidates into a void-free laminate. A frame is molded under internal pressure at the factory; since a repair has no access to the inside of the tube, even external pressure is the closest an aftermarket process gets to how the frame was originally made.

Every structural repair we complete is guaranteed. If you're not sure whether your frame is a good candidate, send photos before you ship anything — we'll give you an honest read on repairability at no cost.