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  1. #1
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    2 Iron Horse MKIII's....2 cracked rear triangles. What to do?

    I am riding a 2006 MKIII sport and have been for about 2 years. At first I loved it so much that I convinced my buddy to grab one as well. Loved the bike, until last week. He loved his 2007, until last week.

    He was cleaning things up and he noticed a crack on the right side of his rear triangle above the chainstay. A complete crack right above the weld. I thought it was a fluke, so I checked mine....a freaking 3/4 crack! Both frames cracked at the exact same spot....design flaw much?

    I am confused as to were to go from here. I know my frame is no longer under warranty, but do they sell rear triangles? Should I even bother since it will likely crack at the same spot. Have they fixed the defect with the newer years?

    Very frustrated right now....when the rage calms down enough for me to snap a pick I will.
    X-prezo Super-D, 26in style.

  2. #2
    Fragglepuss The Chaste
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    There are numerous companies out there who repair frames-assuming yours can be fixed. Given the current situation you may have better luck going that route (cost and turn around time) anyway. I would expect that if you do go that route, that you'll have an area where the repair was done down to bare metal and it may look a little rough depending on the experience of the welder and where the frame is cracked. So while you're waiting for your swing arm to return, you can spend some time at Checker/Auto Zone matching cans of Krylon.

    Take some up close digital photos, round up a box and some bubble wrap, do a search on Google and start inquiring.

    Or you can sit tight and see what response RS Cycles, or whomever the new owners of IH might be, have to say about past warranty issues. Remember though that anyone who steps forward and picks up IH, which is supposedly bankrupt, probably won't have any legal obligation to cover your bike.

  3. #3
    shredder
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    sounds like it should be a recall issue not a warrenty issue

  4. #4
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    there's a rear triangle on ebay right now, but it's 07
    RIP Adam Yauch

    "M.C. for what I AM and do, the A is for Adam and the lyrics; true"

  5. #5
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    Quote Originally Posted by jimbot5000
    sounds like it should be a recall issue not a warrenty issue
    Can't have a manufacturer recall when there is no company anymore.

  6. #6
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    I just found this little gem on mine sunday night,...after reading about a cracked swingarm on this forum. Went to the cave to check my frame, and sure enough, a crack. Spoke with RS, and I am at their mercy. Although, I am kinda thinking I am screwed, so I am looking for a new frame. Something not IH.
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  7. #7
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    Change to a Giant Reign or Reign X, perhaps even a Glory...at least you assured quality and a life time warrenty with some of the best CS in the industry with usually a quick turn around time depending on the situation and parts available for various specific models as such.

    Sorry to hear that everyones IH is cracking and falling apart...good luck trying to get your bikes replaced.

  8. #8
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    That is the exact spot of both my 2006 and my buddies 2007. Definite design flaw.


    Looking into people around here that weld and also looking into new frames. Right now Heckler is in the lead due to my budget.
    X-prezo Super-D, 26in style.

  9. #9
    AKA; Jimmy Tango
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    It was real nice while it lasted...
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  10. #10
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    I am not giving up on it....I talked to someone who knows welding and they say it can be fixed relatively easily by a machine shop...basically just grind away and add in.
    X-prezo Super-D, 26in style.

  11. #11
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    Yes, but then the whole rear triangle has to be re-heat treated to give it its tensile strength so tp speak.

  12. #12
    Fragglepuss The Chaste
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    Quote Originally Posted by y0bailey
    I am not giving up on it....I talked to someone who knows welding and they say it can be fixed relatively easily by a machine shop...basically just grind away and add in.
    So long as they are a certified TIG welder and aren't cross-eyed, you'll be fine. I've had 2 friends who've gone this route and although not the cleanest fix aesthetically, both of their bikes are still going strong and their breaks were a lot worse and on a bigger section of swing arm than the photo above. Pinched/crimped downtubes, top tubes and seat tubes might be a different story.

    I think both paid around $30 locally and had their frames fixed within a day or two.

    Even under some of the best warranty situations, most consumers pay for shipping to the manufacturer and don't get their parts back for several weeks-if they're lucky. There are few exceptions to this situation, like Turner and Ibis, but most can't turn them quickly.

  13. #13
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    Quote Originally Posted by Sim2u
    but then the whole rear triangle has to be re-heat treated to give it its tensile strength so to speak.
    Maybe, and maybe not. It depends on the alloy. Some aluminum alloys (like 6061) need heat treatment to restore strength after welding, some (like 7005) don't.

  14. #14
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    True, yet the majority of most bikes are made out of....
    Last edited by Sim2u; 04-09-2009 at 12:55 AM.

  15. #15
    Cut Casing Whisperer
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    Sorry for you guys...

    P

  16. #16
    GAME ON!
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    Quote Originally Posted by byrdwyngs
    Maybe, and maybe not. It depends on the alloy. Some aluminum alloys (like 6061) need heat treatment to restore strength after welding, some (like 7005) don't.

    6061 is the guilty alloy in this case
    RIP Adam Yauch

    "M.C. for what I AM and do, the A is for Adam and the lyrics; true"

  17. #17
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    The part can be rewelded and re-heat-treated. Some gusset's can be added to the area also.
    Find out where US made frames are heat treated and get them to run the repaired rear triangle. Then have it powder coated.

    My buddy has to have his rear triangle repaired by Foes and they rewelded it and then had it heat treated and powder coated.

  18. #18
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    I have emailed IH to see where to go from here....hopefully they give me some decent information.
    X-prezo Super-D, 26in style.

  19. #19
    Fragglepuss The Chaste
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    Quote Originally Posted by y0bailey
    I have emailed IH to see where to go from here....hopefully they give me some decent information.
    You might want to check some of the other threads on this site for a history lesson. As of right this minute, Iron Horse is no more.

  20. #20
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    Found a TIG welder in the area who builds custom motorcycles....I think he can handle the job.

    While taking apart the rear triangle I found another beauty of a crack...right side, front of chainstay. This thing is trying to make me buy a new frame. I am still going to weld her up and keep it running as a backup bike, but it is sad that it has come this far. I do ride this thing hard however, so I cannot fully complain.

    Newly discovered crack


    Older crack
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  21. #21
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    That is definitely a recall issue...yet now that company has folded, you really have no other options as such. And this design has been brought over to another company in many respects with a slight Giant tweek in terms of aesthetics.

    Bro, I really feel for you and the other chaps as I really would go ape-sh!t if I found flaws on my bike after casing various designs and chose one that decided to break apart under the riding conditions it was designed for.

    the custom motor bike builder, did he say that he will bake the frame after the initial welding was complete...? I mean I am sure he will though, but it may be worth mentioning it just to be sure though.

  22. #22
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    We will see tomorrow....he assured me it would not look stock, but it would be strong as hell. I trust him. Plus for $30 who cares!
    X-prezo Super-D, 26in style.

  23. #23
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    Do be sure though, because the weld could cause other areas to fail.

  24. #24
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    Yea....I will ask him for more information when I drop it off tomorrow.
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  25. #25
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    What was the result. Facing the same problem now.

  26. #26
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    Let's just say I am now ordering a SC Heckler as we speak.
    X-prezo Super-D, 26in style.

  27. #27
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    Details? Not possible to weld? Heckler is on my short list along with the Giant Reign. Like the simplicity and supposed durability of the Heckler but do not know how it would peddle up hill. That was one of the things I liked about the DW link suspension, no bob.

  28. #28
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    It is possible to weld but it also needs to be heat treaded after the weld...not too sure who or how much it would be inyour area but, from what others are paying you may be in for about 30 up to 50$...? Situational based.

    Myself, after owning quite a few of the more boutique brands with their limited warrenty and far higher price tags with more lower end specs, I switched to Giant many years ago and I have not looked back. Although, that has never stopped me from buying other brands of course for various reasons.

    If I were you, I would go the reign and this years models really rocks in terms of what you get for the money you hand over as well as that sweet LFTWarrenty, not even mentioning its prowess up the mountain and smile factor down the mountian.

  29. #29
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    Welds just cracked in the exact same spot. Kinda figured it would happen, just wish it wasn't on ride 1.


    Chose the Heckler due to bomb-proofness and the ability to just get a frame. I have all other components needed. Giant won't sell just frames.

    Test rode a Heckler today...climbed like a goat.
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  30. #30
    semantic blockage
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    Can those with cracked triangles describe your riding style, weight, how long your bike's been in service, etc. to give us an idea of the conditions which led to the failure?

    Due to the number of cases cropping up, I'd guess it's a wide range of riding styles, and ages of bikes, etc.. I'd like to (hopefully) gauge the likelihood that mine will fail as well ('07 Comp) - if that's possible. Wondering how widespread this problem is.

    Thanks

  31. #31
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    Holy timing Batman, Iron Horse really got out at the right moment. Right after they leave it's like a chain reaction of bikes cracking. How come this didn't happen to the '07's earlier?

  32. #32
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    Did you get a gusset welded in? Is it cracked in exectly the same spot? Is so the weld was dodgy.

    The rear triangle on the mkiii is asymmetrically loaded that would twist the rear end causing the cracking. I well placed gusset would sort it out.

  33. #33
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    Has anyone actually had theirs welded? Where should the gusset be placed? Should it be reinforced anywhere else? What is involved in the heat treating?

    The bearings in mine were toast. Probably from the rear triangle waffling around after it cracked.

  34. #34
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    ah...just hang it up as wall art and be done with it lol...RIP.


    YoBaily, when will the new rig come in...?

  35. #35
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    If it can be fixed for <$100 why not fix it? The bike rides great and I can not afford a new frame now.

  36. #36
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    Quote Originally Posted by gtdrew
    Has anyone actually had theirs welded? Where should the gusset be placed? Should it be reinforced anywhere else? What is involved in the heat treating?

    The bearings in mine were toast. Probably from the rear triangle waffling around after it cracked.
    No one has actually welded theirs. I feel their frustration but it seems like most just want to complain that it cracked and stare at IH's lifeless body.
    The rear triangle should be able to be repaired. It will just take some legwork to get in touch with a frame maker, repair shop that understands the alloy and can get the RT heat treated.
    Heat treating involves submerging the frame in a heated solution which improves the durability of the material.
    Is it necessary to heat treat? I am not sure but I did ride DH one day with a guy who was beating the crap out of his Intense M1. His rear chainstay had been broken and he had it rewelded and beefed up with gussets and no heat treat and it had been going strong for a long time.

  37. #37
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    I actually welded mine. I didn't add any extra metal to it. We filed out the crack and associated paint and re-welded. Cracked 1/2 through my first ride in the exact same spot. We did not re-heat treat or anything like that.

    The simple fact of the matter is that re-welding is a bandaid over a broken leg. Heat treated or not it won't fix it. It may buy you a ride or two (enough time to save up for a new frame).

    Here is the response from someone who knows their crap about welding
    "It will fail quicker if you try to weld it...better off just to ride it till it breaks. I've been a welder for around 24 years, everything from dirt modified chassis' to pharmaceutical grade stainless steel to the scoreboard/ tv screen at Five County Staduim. I am currently employed as an industrial welder for Hanson Aggregates, so what I am telling you about your frame isn't a offhanded guess, it is a fact."

    I loved my MKIII....I am sad to see it go. It was my first "real" bike. Now time to get a SC Heckler and never worry about it again. We will see if I miss having a DW-link bike....my guess is that I won't.
    X-prezo Super-D, 26in style.

  38. #38
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    Quote Originally Posted by y0bailey
    I actually welded mine. I didn't add any extra metal to it. We filed out the crack and associated paint and re-welded. Cracked 1/2 through my first ride in the exact same spot. We did not re-heat treat or anything like that.

    The simple fact of the matter is that re-welding is a bandaid over a broken leg. Heat treated or not it won't fix it. It may buy you a ride or two (enough time to save up for a new frame).

    Here is the response from someone who knows their crap about welding
    "It will fail quicker if you try to weld it...better off just to ride it till it breaks. I've been a welder for around 24 years, everything from dirt modified chassis' to pharmaceutical grade stainless steel to the scoreboard/ tv screen at Five County Staduim. I am currently employed as an industrial welder for Hanson Aggregates, so what I am telling you about your frame isn't a offhanded guess, it is a fact."

    I loved my MKIII....I am sad to see it go. It was my first "real" bike. Now time to get a SC Heckler and never worry about it again. We will see if I miss having a DW-link bike....my guess is that I won't.

    Sounds like you are throwing out the baby with the bath water. The rear triangle can be fixed. It was welded once and can be welded again. But it needs a proper welded gusset not a welding on the same weak spot. A plate of some sort needs to be welded over the area.
    I don't blame you for being over it. The frame is only worth~$300 anyway with IH finito for now. But a grind down and reweld is not the way to fix it properly.
    Oh and Never say never!
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  39. #39
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    If you look at my above pics, pic 1 is in no position for a gusset. It is at a critical point where the wheel, the dw-link, and pretty much the back half of the bike staying together is at. I find it difficult to believe you would be able to fit a gusset there, let alone do a few drops knowing that your bike has a bandaid on it.

    As for the SC frames breaking....it happens. But that company will be in business for a long long time and their CS is amazing. That is why I chose them. I have emailed about 200 IH people and haven't gotten a single response...because surprise surprise they are out of business.

    Weld away people...I did, but don't complain when you ruin a nice wheelset or a leg due to something else failing.
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  40. #40
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    Quote Originally Posted by y0bailey
    If you look at my above pics, pic 1 is in no position for a gusset. It is at a critical point where the wheel, the dw-link, and pretty much the back half of the bike staying together is at. I find it difficult to believe you would be able to fit a gusset there, let alone do a few drops knowing that your bike has a bandaid on it.

    As for the SC frames breaking....it happens. But that company will be in business for a long long time and their CS is amazing. That is why I chose them. I have emailed about 200 IH people and haven't gotten a single response...because surprise surprise they are out of business.

    Weld away people...I did, but don't complain when you ruin a nice wheelset or a leg due to something else failing.

    Sorry Y0bailey, I thought that you had an 07 RT and it had cracked in the typical right side chainstay junction. That spot certainly is a candidate for a gusset plate. But the other area you show is definitely not.

  41. #41
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    Ill have a look at where I think I gusset should go into the frame. Maybe ill get a mechanical engineer to have a look at it as well. I can visualise the issue just need to work out where is the best place for a gusset to redistribute the load without putting too much stress on another area.

    Y0baily – Which part re cracked? Did it crack in exactly the same spot? As in through the weld that has just been put in or just above in the fatigued metal? It should not have cracked through the weld. I am at work and can not see your pics, will have a look when I get home. The two cracks could also be related, once the first is there it could transfer the load to another spot that would deflect & crack.

    The usual crack in rear triangle can definitely be fixed. The crack is a fatigue issue, it does not snap in two and people still ride there bikes with the crack. This gives clues to the stresses in this area.

  42. #42
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    Did they fix this issue in the 08 models? Has anyone with an 08 had a frame crack? I have an 08 and I'm wondering how worried I should be.
    Gotta get up to get down.
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  43. #43
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    Quote Originally Posted by Qui'lan Fett
    Holy timing Batman, Iron Horse really got out at the right moment. Right after they leave it's like a chain reaction of bikes cracking. How come this didn't happen to the '07's earlier?
    seriously. It makes you wonder, doesn't it?

  44. #44
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    My bike is an 08 frame. Exact same crack.

  45. #45
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    OH....Boy!!!! Yikes....!

  46. #46
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    Im sorry to hear all this bad news guys.

    If any of you lived in the Bay Area I would gladly help you out. Know my way around TIG.
    Gamut
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    Formerly: motormonkeyr6

  47. #47
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    Quote Originally Posted by gtdrew
    My bike is an 08 frame. Exact same crack.
    I thought this was only for 06 and 07's. Anyone else crack an 08?

  48. #48
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    i have a 07 MKIII and after two seasons there is no crack!!!!

    Keep it real guys - you can break everything. Maybe it is a weak place of the MkIII but this does not mean that every single triangle will break!

  49. #49
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    Quote Originally Posted by motormonkeyr6
    Im sorry to hear all this bad news guys.

    If any of you lived in the Bay Area I would gladly help you out. Know my way around TIG.
    Get a heat treat oven and you might be able to put away a nice chunk of change in the coming future.

  50. #50
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    Quote Originally Posted by Jerk_Chicken
    Get a heat treat oven and you might be able to put away a nice chunk of change in the coming future.
    You can single handedly replace IH customer service! It won't take much!
    X-prezo Super-D, 26in style.

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