I started the repair process today, although it's not as straightforward as I had hoped. In order to insert the new piece of reinforcement tubing, I had to cut out a section that was dented in during construction, to provide a place for the seat's crossbar to embed into at the time (it's not used that way now).
I measured the diameter as well as possible, using a pair of pliers to hold the tube and a ruler across the far end of the pliers' handles, then measured the various bike frames I have, and settled on the seattube from an already-chopped-up Mongoose as the best fit to go just inside the toptube but still be friction fit, requiring a hammer to install it. But when I cut it and test fit it, it was LARGER than the toptube! How does this happen?
I dunno, but anyway I then used that tube to compare for other tubing, and found some EMT conduit that would easily slip inside the Mongoose tube, and thus ought to fit inside the other--and it almost did, but not quite. So I had to slit it, and I couldn't get the tube to stay in the vise to cut it with the hacksaw, so I had to use the angle grinder to do it. Of course, I could not find the cutoff wheels, or any of the wheels for it, and only had the well-used gridning wheel on there, which cut a WAY too wide slot thru the tube lengthwise, but at least it was done.
Well, almost done. About halfway thru, my hands did their "thing" and I couldn't hold onto either the tube or the grinder, and hit the inside of my forearm with the grinder, taking the skin off a few square inches of it.
Didn't hurt a bit when I did it, but I knew it would as soon as I touched it with anything... So first thing I did was go cut off a couple of Aloe Vera leaves, and slit them in half lengthwise along the flats, to expose a broad surface of the gel inside. Then I scraped that gel until it was all gooey liquid, and smeared that on the raw area, which hurt like a @)(&#&@#%#@&%(_@#&%)(@#)#%R()@ and I cried but it was done.
Three of the dogs were all around me worried at my noises which were probably scary, because Loki wasn't anywhere to be seen. Fred and Nana were looking like they might not be happy with each other so I had to put Fred up in teh bedroom, whcih she had somehow gotten out of not long before.
Here's Hachi and Nana after settling down finally:
Anyhow, I then cut an old worn-out sock for the elastic top part, and used that to secure another Aloe Vera leaf, also split in half, gel-side onto my raw arm, to let it help heal it. I've found that fresh real live AV does WONDERS for raw skin wounds, burns, etc. Much much better than any of the first aid treatments or antibiotic ointments, etc. So I keep a bunch of them growing in both front and backyards. Real handy to have, as clumsy as *I* am.
Finally I was all bandaged up, but the throbbing was too much, so I decided to wait on going back to cutting the slot. I had not had a chance to really play with that telescope left on my porch the other night by some nice person, so I dug out an old big heavy videocamera tripod (the kind used for those old 3/4" cameras that probably weighed 50 pounds and were bigger than my dogs), and some zip ties (wanted to use hose clamps but can't find them), and put the TS on the tripod, took it out back, and set it up to stargaze.
It was just getting past full dark after sunset. About the time I finsihed setting it up, and was trying to focus on some points of light, they got blurry and vanished.
My first thought was GREAT NOW I'M GOING BLIND, TOO! but no, it was just clouds. Clouds everywhere, probably forming as the humidity condensed as the air cooled rapidly up there after sunset. So much for relaxing stargazing.
By this time it was time to feed the dogs, whcih nowadays also means coaxing Hachi to eat, as she no longer inhales her food like she used to, and I have to stay with her to talk to her while she eats, or she just leaves. She still has a heck of an appetite, just doesn't want to eat without me there, I guess. I dunno what the deal is.
Finally, once that was all done, I just said heckwithit and cut the slot, and then I could squeeze the tube to get it into the toptube. But fitting it in there was not as easy as all that. First I had to lift up the whole center and front of the bike, and bend down the front end to give me space to insert the new tubing inside the front part of the toptube, and then lower it down into the rear part of the toptube.
I had hoped to do it by taking out the toptube and steering from the seattube at the front frame, but there was no way I could insert the very long seatpost that's part of teh steering frametube down into the seattube once the reinforcement tubing was installed--the only choice was to bend the entire front frame downward at the former chainstay points at the front BB, then back upward to put it back together with reinforcement tube already in the front toptube, pushing it (with a sledgehammer on the front of the seattube/steertube assembly, inline with the toptube) into the rear stub of toptube still present on the rear half of the frame.
This worked, and so now the reinforcement tube is in place. But since I had to split the tube to get it in there, it's not as strong as it originally was, even after I weld it into place (which might happen tomorrow, I'm too wiped out to do it tonight).
Oh, and in the process of retightening the seattube/seatpost/steering clamp bolt,
I managed to whack my eyebrow area with the end of the ratchet when it slipped off the nut. Took about ten minutes to stop dripping blood; was worried I'd have to superglue it to fix it.
So some extra reinforcing triangulation bars are going to be added--these black tubes, formerly off the old futon daybed frame I think I have pictured in the new Full Suspension Cargo Bike thread, will go from the front ends of the square tubing used for the cargo pod rails, down to the chainstay meetup points with the front BB. That should effectively triangulate this area in 3 dimensions, and help prevent a future failure of the same type.
I'd also like to add triangulation from the same rear points up to the point the toptube joins the steering point/seattube, but I can't find the rest of the pile of those black tubes. Gotta be here somewhere, but I still have huge piles of stuff scattered all over that isn't yet in it's new place, after moving the bedroom into what used to be the bike workshop, and all those parts are everywhere in the house until I rearrange the backroom to be the new bike workshop.
Anyhow, I can't weld it until I wheel it out the front door, around the side and thru the backyard to the only 220V outlet I currently have for the welder. Theoretically I could run the cord for the welder thru the bathroom window and then the hall and into the front room, but it won't reach out the front door, and it would be bad for a number of reasons to be welding inside the house like that.
For now, it sits like this, without the seat on it:
I passed by the frame for hte full suspension new bike a few times in all this, and kept considering just finishing it up as a hardtail, instead, without the NuVinci, or some other variation of rear suspension using just a regular biek triangle and BB as pivot, etc., instead of fixing CrazyBike2 up. But there is so much work left to do on that frame, and I don't yet even know if it will turn out rideable with it's current geometry. So...I left it where it sits for now. If I had another week's vacation I coudl take right now, I would consider doing so just to build it up as a CB2 replacement witout all the fancy stuff I envision for it, and build another one to do all that instead. But I don't, and coudln't take it right now even if I did. So...hopefully tomorrow I can weld up CB2 and see how it rides again.
In the meantime, I've injured myself much more today FIXING the bike than I did when I CRASHED it. All I got then was thils tiny scrape, which is already half-healed with the scab peeling off.