Carbon - the high-tech material

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 · 09.08.2003

Carbon - the high-tech materialPhoto: Daniel Simon
The high-tech material carbon requires a high level of expertise not only in design and production, but also in assembly. TOUR shows you how to avoid mistakes.

The black material is light, strong and beautiful - but also sensitive. This means you have to rethink how you assemble and use it, as carbon behaves differently to metal. One important point: carbon does not deform permanently when overloaded. Where metal bends or dents, indicating damage, carbon fibre deforms elastically until the first fibres (audibly) tear. Even then, carbon fibre components often return to their original shape - but safety is no longer guaranteed: Time for replacement.

The carbon surface also requires careful handling. Because CFRP components are bonded, they can usually only be painted with paint that dries in the air. Such paintwork is sensitive and flakes off relatively quickly if the bike hits something.

Assembly methods similar to those used for metal parts, but above all careless handling of lubricants, are further hazards for the sensitive material. It is important to ensure exact dimensions when combining carbon parts with other metal or carbon components. If metal parts do not fit together, assembly mishaps can lead to dents and scratches, and the function may not be maintained. However, a carbon seatpost that is squeezed into a seat tube that is too large or too narrow will be irreparably damaged even before the first metre has been ridden. In addition to seat posts, this applies above all to forks, stems and bottom brackets.

Degree of difficulty: Professional level

You will need:

  • Tools: Inner bearing and fork assembly are jobs for real professionals. You will need a complete set of tools with all the bearing spanners; no prior knowledge is required for the maintenance work

Carbon assembly tips

1. assembly stands can become a tube killer; therefore, carbon frames should only be clamped to the seat post. A cheap seat post with a solid wall thickness that fits the frame perfectly in diameter is suitable for assembly work. It is also pushed into the frame with absolutely no grease. Incidentally, this recommendation applies to all oversized frames with thin walls, even if dents in the metal tube are generally only ugly, but do not mean the end of the frame.
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