On 3/21/2018 6:41 PM, Jeff Liebermann wrote:
On Tue, 20 Mar 2018 13:45:06 -0700, sms
wrote:

On my DaHon Speed TR folder, it had brake levers, branded DaHon with a
longer handle than other levers I've seen, about 1" longer. One of the
levers broke in half and I haven't been able to find a suitable replacement.

No clue on a replacement, but if you still have the remains of the old
lever, it can be repaired in various ways. I had one I fixed by
drilling both sides of the break. On the thick side, I drilled it for
an interference fit for a roll pin. On the other side, I drilled it
loosely because it's very difficult to get the holes aligned on the
same centerline. I then filled the hole and mating surfaces with
structural epoxy and allowed to harden for over 24 hrs. I'll see if I
can find it and take a photo. However, there's not much to see. Just
a crack that goes around the lever.

Another way is to TIG weld the two pieces together. I haven't done
this, but have seen the results. If it's done professionally, it
should look good and hold together quite nicely. You'll probably need
to know the Al alloy. My guess(tm) is forged 6061-T6.

That probably sounds terribly risky to some people, as in "But what if
the lever breaks at the repair???"

But in any normal use, the force on a brake lever is quite small. A
strong person can bend many designs fairly easily. I did that on the
levers on my wife's touring bike, to better fit her smaller grip. They
don't have to be super-strong because you'd go over the bars if you
squeezed too hard.


--
- Frank Krygowski