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Long Brake Levers
On Wed, 21 Mar 2018 19:44:01 -0700, Jeff Liebermann
wrote: On Wed, 21 Mar 2018 21:20:19 -0400, Frank Krygowski wrote: That probably sounds terribly risky to some people, as in "But what if the lever breaks at the repair???" I'm sure the TIG welding will hold together if there's sufficient penetration. The epoxy glue job is a bit risky depending on temperature. The difference between the coefficients of thermal expansion for aluminum at 23 PPM/C and epoxy[1] at 95 PPM/C could easily tear apart the glue joint when hot or cold. Looks like Masterbond has several low CTE range epoxies: https://www.masterbond.com/properties/epoxies-low-coefficient-thermal-expansion which are a bit too low but should work. If that's too much work, just mix in some powdered aluminum into the epoxy mix, and it should bring the CTE of the epoxy down a little. If that's still to much work, use the largest diameter roll pin as possible. 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. Agreed. I don't think grip force is going to bend or break the levers (under normal use). More likely, impact damage from dropping the bicycle on the brake levers will break the joint. Epoxy is rather brittle and will crack before it bends. If that's a problem, a thin strip of aluminum, glued over the joint, should help protect the glue joint. [1] MG Chem 9200 structural epoxy adhesive: https://www.mouser.com/ds/2/265/tds-9200-2parts-1149953.pdf A set of epoxy adhesive 832FX-450ml costs $46.03. A set of XLC brake levers Brake Lever set for V-Brake BL-V05, at Amazon is $12.59 :-) -- Cheers, John B. |
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