The bottom bracket shell on this frame had given way and was being pushed inside. When I stripped the damaged carbon back it became clear that the frame hadn’t been laminated properly in manufacture so had a weak spot built into it.
A temporary mould was made from thermo forming plastic to capture the shape of the area that needs to be recreated.
The damaged carbon was removed. The layers of carbon in this area weren’t overlapping but were instead butted up to one another making it weak
Fresh carbon was put in place and I also took the opportunity to reinforce the area internally as the inside of the shell provided a much greater surface area.
Matte black paint matched and blended back in.
