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  1. #1
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    Resurrecting a old Cannondale Barloworld System Six

    I got my hands on a old Cannondale Barloworld System Six, frame looks to be in almost perfect condition, apart from the headset, which, I am not sure what happend to it. It looks like the previous owner tried to pry out a headset expander plug with force or something, and seriously damaged it. The forrk tube and frame however have no damage.

    I would love to be able to save the frame and build it up, but have no idea how to remove the damaged expander.

    Anyone have any ideas?

    Resurrecting a old Cannondale Barloworld System Six-img_6739-2.jpg

    Resurrecting a old Cannondale Barloworld System Six-img_6740-2.jpg

  2. #2
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    Quote Originally Posted by phazer View Post
    I got my hands on a old Cannondale Barloworld System Six, frame looks to be in almost perfect condition, apart from the headset, which, I am not sure what happend to it. It looks like the previous owner tried to pry out a headset expander plug with force or something, and seriously damaged it. The forrk tube and frame however have no damage.

    I would love to be able to save the frame and build it up, but have no idea how to remove the damaged expander.

    Anyone have any ideas?

    Click image for larger version. 

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    Click image for larger version. 

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    You need to cut the expander plug in two or preferably more pieces from the inside, and small cutoff wheel would like do the trick, slower would be a hacksaw, cut out a piece or two.

    Be extremely careful not to nick the steerer tube which appears to be carbon fiber... if you can cut it, then collapse the aluminum expander tube with a pair of vice grips or clamps.

    It will remove easily when cut and compressed.

    take your time, don't beat on it and deform the steer tube or ding it, or the frame... if you don't have the tools, find someone who does and is competent to use them...

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