So I have created a work around which, while it may not pass as a “restoration”, both works and doesn’t stand out as a patch job without a second look. The key is that the brass end of the original DT shift boss is still usable.
Parts - all bolts match thread pattern of the
- Original brass fixture
- Cable stops
- Generic curved DT shift boss (bought a pair at Framebuildersupply.com)
- Shimano SL-7800 shift lever boss cover
- 2” bolt (length may vary depending on frame diameter)
- .6” bolt
- .5” bolt (original)
- Old tube
- JD Weld steel formula
- Thread-lock
Instructions
I neatly cut the head off the bolt leaving a 1.5” threaded post. (Same length as my original post.) I attached the post to the generic shift boss with the JD Weld making sure not to thread it too deeply. Because the curve of the frame and shift boss don’t match exactly, I cut a gasket from the old tube to protect the frame. Thread the post through the frame and attach the brass fixture using JB Weld. Make sure not to over tighten.
Place the shimano cover over the generic boss stop and attach the cable stop using the.6” bolt. Install the cable stop on the brass fitting side with the original .5” bolt. Use thread lock on each.
The shimano cover is slightly thicker than the original covers. I ground the lip off the edge of this with my Dremel although it wasn’t entirely necessary. Removing the lip does help to keep the cable stop from rotating due to the square structure. I will clean this up better before final assembly. Regardless, the longer bolt was necessary due to the increased width.
Finished, this is attached solidly, isn’t rotating, and if the need arises it will be easy enough to drill out the generic shift boss end.