Stickin' that tail back on

[brimo]

Been thinking about this for a while and looking at some way that you can put the tail back on  again without welding and have a couple of ideas floating around in the old grey matter. I know there's some concerns with resale value after a mod like this but I do like the look of the tail chop. The main problem seems to be getting a good clean cut on the frame tubes and being able to butt them together without it looking too ugly so am looking to make a colour matched sleeve that'll go over the joins with a steel or alloy piece to go inside the frame tubes. Should be a piece of piss and be just as strong as the original.
Anyone had any similar ideas? One thing I do need though, if someone can help out, is the internal diameter of the tubes where you've cut them. (An accurate measurement with some verniers please.)
> edit:  and if anyone still has the bit they cut off and would like to sell, lend or donate it to a worthy cause, that would make my job even easier. You would be the recipient of the first one I make. 

[mattyvas]

18mm I think, cause I got frame plugs to match the rest of my bike and the smallest was 20mm so I had to adjust them to fit.

[MonsterDorf]

Been thinking about that as well.

I've considered "sleeving" it and also drilling and tapping and putting very small grub screws in to hold it all in place (from the bottom) - just an idea.

[sydmonster]

+1 on the inner sleeve idea. Then pop rivet throught the bottom and painted over for a seamless look. I would avoid a sleeve on the outside as it's more noticable.
 The other item is permi-fix or chemi-weld. This is a chemical that bonds surfaces, as it is an industrial strength glue. Put in the inner sleeve apply chemi-weld and splip on cut off tail half. Allow to go off, paint as needed. No welds & no screws. But harder to reverse.... something to think about. - Chris

[tricolore]

Surely a dowel with screws or rivets will secure the piece. Consider tube cutters when cutting the tail... I am a plumber and we have tube cutters that with patience should cut the steel, usually used for copper though I have personally cut stainless tubing with them, may mark the paint though , reco test run first.They will ensure a straight cut so when you re join it the two pieces should marry together nicely, certainly better than grinder/dremel cuts. Pick up a decent pair at your local plumbing supplies for around $50.00 or alternatively make friends with a plumber.
Good luck.

[monstermick58]

Sleeve it for sure, but any decent welder could weld the portion back on then its just a matter of grinding the part back down, prime it then paint.

I think the other ideas sound a bit dodgy

My 2c worth





                                                   Mmick

[brimo]

Mick, my idea was to make something that the backyard person could use without having to resort to welding and or painting.

[loony888]

using a sleeve that fits the I.D snug and drilling small holes in both parts of the frame either side of the cut then tapping said holes with a thread for grub screws will work and is straight forward enough, at least there's no grinding and paint touch ups to do.
a simple spot weld on the underside of each tube is very easy too, i would still add the internal sleeve for added strength.  just remember to disconnect the battery before welding.



paul.