Often times frames come in for carbon fiber repair, and the customer has no idea how it could have broken. This Orbea Orca is just one of those cases. The customer did not even see it until it was in the shop for a winter overhaul. Our guess was a frontal impact situation, but they said it has never been crashed or ridden hard.

Normally, the lunch ride is a beautiful thing. Some of us are lucky enough to take a break for an hour, kit up, chase some wheels and mess around with friends and co-workers. It's nice to burn off all that extra coffee energy and earn your lunch while you're at it. Friendly competition (read: hammer throwing and sprints) always seems to be part of the lunch ride experience, maybe beca...

Headtubes on cross bikes get banged up pretty badly...and that's just the nature of the CX beast. Fortunately, we're able to save almost any carbon fiber structure, so this headtube was a common repair for us! This one required immense patience when removing the damage, an accurate layup, and usually an interesting way of extracting the resin from the laminate. This Felt F4x arrived f...

At Ruckus Composites, we pride ourselves on quickly and safely repairing carbon fiber bike frames. It is our continuing mission to use carbon fiber repair to challenge the status quo of both the bike industry and throwaway culture by keeping good bikes and their memories rolling. Our proven carbon fiber bike repair process goes like this: first, we inspect the damaged area using ult...

Headtube repairs are some of the most complex repairs we perform; they require immense patience when removing the damage, an accurate layup, and usually an interesting way of extracting the resin from the laminate. This Cervelo arrived for carbon fiber repair and we were able to turn it quickly and cleanly. At Ruckus Composites, we pride ourselves on quickly and safely repairing car...

Unfortunately, this is a repair request we see WAY TOO FREQUENTLY: shipping damage. No matter what you do to pack your bike safely, snugly and correctly, there's always a chance an accident can happen. In this repair case, the set of handlebars smashed into the bottom half of the headtube, causing a slightly-larger-than-quarter sized crack. Luckily, we're here to help. This carbon fib...

This carbon fiber Trek Madone was damaged due to rear derailleur failure, resulting in a crash. The resulting tumble also caused damage to the headtube. This bike is the favorite ride of one of our customers and she sent it to us to be remade again.

This week we worked on a number of cool repairs. One of the most interesting projects we completed was a full head tube replacement on a Look KG 386. The bike arrived here with a broken 1” head tube in need of repair. This older 1” standard means that it’s hard to find compatible parts...