The motto around the Ti Cycles shop is "Anything Is Possible". If something was made once, it can be made again.
One of the more complicated frame repairs in recent memory was a composite Lemond Tete de Course, half titanium and half carbon fiber, that required a downtube replacement.
Before we could replace the titanium tube we needed to un-bond the top of the frame from the bottom. For this task we called on our friends at Ruckus Composites here in Portland, masters of the art of carbon fiber.
The carbon sections needed to be out of the frame, but able to be put back in to place to set up the frame jig for welding the new downtube to the original bottom bracket shell and head tube. During this process while the downtube is out of the frame the head tube is completely disconnected, as are the carbon fiber tubes, meaning the frame is almost completely disassembled. Only the chainstay welds at the dropouts and bottom bracket shell remain from the original assembly.
After the new downtube was installed the titanium sections were brushed up to a beautiful shine and transported in a box back to the Ruckus labs for the carbon fiber reassembly. Then the frame came back to us one last time for final detailing and wax anti-fingerprint sealant before heading home to its owner.
"Everyone is impressed with the work and craftsmanship of Ti Cycles, as the frame looks beautiful. Your service and final product was excellent."