Calfee has been building carbon frames in the US since 1987 and repairing them since 2003. With thousands of frames repaired, they take pride in the work they do. All repairs are backed by a 10yr warranty on the repaired area. Repairs are easy. We send in a bare frame and they assess the damage. Prices can vary from $200-$400 depending on the extent of the damage, paint and color matching can be done for as little as $75! There is an initial inspection fee of $50 that can be applied toward the repair. After the initial inspection, a 60% deposit is required before work is started. Turnaround time is usually 7-10days.
"We are proud to offer the benefit of our 20 years experience with composites to the owners of all carbon bike frames. Many major carbon frame companies refer riders to us for their frame repairs, and to help solve design issues. Hundreds of bike shops from across the U.S., Canada, Asia, and Europe have been able to provide their customers with an affordable alternative to Crash Replacements. Our molding process uses the best quality 3k carbon fiber weave to create forms that are shapely, lightweight, and extremely strong. From minor scratches to stuck seatposts to frames destroyed by the dreaded endo or that startling encounter with the garage door; we’ve repaired over 8,000 frames since 2003. Gone are the days that a small puncture or fracture in a multi-thousand dollar frame renders it trash. Calfee’s extensive experience with composite materials means we are able to repair nearly every frame, regardless of manufacturer. In addition to frames, shoes and carbon wheels can be repaired as long as the damage is not along the breaking surface of the rim. Calfee uses an unique molding and compression process of 3K carbon fiber weave to repair damaged areas.
The damaged portion is sanded away, plus an area about 1-1.5 inches around the crack. The sanding tapers from the original, full thickness carbon down to the removed damaged area. This removes any stress risers and prevents them from creating fractures again. Next, new carbon can be laid down. The laminate is rebuilt by reading the original fiber orientation to match with the new layers. After the area is built back up, it is sanded a final time to meet the same contours as the original frame. The top layer of carbon does not always match the same weave as original. This may alter the cosmetic appearance if the area is only clear coated or left unpainted.
After the new carbon layers are laid, the area is compressed with tape to set. For fractures around lug areas or with a unique shape, a custom mold is made to adequately and evenly apply pressure. In cases of severely damaged frames the area can be reinforced from the inside out with an insert; often made of foam or carbon depending on the nature of the damage. Sanding a long taper prevents stress risers, which can cause failure. This combined with well laid carbon layers means long lasting results. Though testing, it has been found that repaired areas meet the same degree of stiffness as the original tubing. With carbon this generally means they will also meet the same fatigue life. Many of the same technicians that have build Calfee frames during the last 25 years lend their expertise in the repair department. After so much time, it is now a honed craft. Once the repaired frame has been inspected, it goes through paint which is housed in the same building. Paint can range from a simple clear coat, to replicating the original design and details, to an entirely new paint scheme."