Broken downtube shift lever boss for a '95 R300

[N8than]

...at least I think it's called a boss. It's the threaded post lever attaches to. Cannondale no longer has them. Any ideas where I can get one?

Thanks,
Nathan

 

[black lightning 1987]

I have a used one. It's something I can probably duplicate.

 

[N8than]

Great. If the used one is in decent shape, I'd be interested.

 

[black lightning 1987]

Mine has an issue. The die-cast boss came apart when someone removed it. Click on the thumbnail for disassembled view. There is still enough thread inside to hold, but I would probably remove the broken bit from the threaded stud and epoxy the stud into the die-cast boss. The threads on the other boss are steel, so no problem at that end.

 

[black lightning 1987]

If you are using STI or Ergopower shifters, I can make something to mount the cable adjusters without the stock bosses.

 

[N8than]

I'll try anything at this point. Just want get back on the road. Attached is a shot of the shift lever that came with the bike.

 

[black lightning 1987]

I'll assume that you want to continue to use down tube shifters.

Have you taken your shifter boss assembly apart? I'd like to see where it failed.

 

[N8than]

Here's the post on the bike and the lever disassembled.

 

[black lightning 1987]

Looks like yours failed in the same place as mine. You can extend the threaded rod farther into the broken boss. If you go too far you may have to shorten the shifter mount screw.

 

[black lightning 1987]

Here is a cheap replacement:

https://www.cycle-frames.com/bicycle-frame-tubing/NOVA-LEVER-BOSS-KIT-FOR-AL-FRAME.html