Have Trek 920 frame, need to (re)build bike.

[natethegreat]

My green Trek 520 bike  frame broke from about 10K miles use, but instead I was offered a new Trek 920 frame.  But nothing fits this Trucker style frame.

Instead of a simple Trek dropout repair I am faced with a total rebuild of a previously Shimano LX bike groupset, and my 700C QR Velocity Chukker wheels.

The 920 frame (also discon but good) has Thru hole axles, a new hollow crank design, derailleurs, and 160mm disk brakes.  Maybe I can save the seat and handlebars?

Can anybody suggest a practical methods get these components fairly inexpensively for a rebuild?. It looks like a >1K replacement cost. :<(.
Wrecked frames, craig's list, strip a Decathlon 520 (cant buy in US)?   I can build wheels, and have tools.
https://www.trekbikes.com/us/en_US/bikes/bikepacking-touring-bikes/920/920/p/21996/

Nate

[John Nettles]

So sorry to hear about losing a nice bike.  If there is a bike from Trek you like, maybe you can write them and explain the situation and see if they will sell you a complete bike at or near cost or offer what you think it is worth.  You can hint around without being too obvious that you are also asking on the bike forums since you are in the situation what others think. 

Other than your ideas for sourcing the parts, I would consider pawn shops too but that may take a couple of months to source. 

Hope it works out well for you.  Keep us informed as to the resolution. 

Tailwinds, John

[avrin]

Trek frames, at least in steel, have lifetime warranties. They have 520's for warranty replacement in stock, even though they are no longer sold. I know whereof I speak.  My 520 failed a few months ago, also with about 10k on it, and Trek replaced it with a favorable warranty determination within 24 hours, and I had the new frame within a week.  There was a substantial labor cost to put on the parts from the old bike, but I was pleased as punch.

[natethegreat]

I broke it at the rear dropout, and it was a '94 Trek 520. (some wheel issues early on like all 94s).
I was told that they did not sell 520s and frames of this size (58cm) were not available. There was no quibble about liability.
First they offered a rando bike frame, but the carbon fork had feeble looking mounts for racks.

I heard they had 920 frames (also discontinued) but of a touring design so I chose that option in a 56cm, since 58cm were not around. But no intact 56cm Trek 520 bikes (or 920 bikes) were available to up buy into. So that is my situation here in DC.

With either 520/920 design, since they did not repair the old frame, all my old components like QR wheels do not fit on the new thru hole axle disc brake frame and I am kind of stuck.

Maybe Trek can sell me the replacement components for a 920.  I have no problem doing the labor, but just need the parts.  If I pay for both I bet it would be 2K, and then I might as well of bought a Surly LH Disc Trucker or the likes.
I will inquire or maybe you have a tel/email contact?

[natethegreat]

Well, as I took apart the old 520 frame for exchange, I could not but appreciate the heft, stiffness, and burlyness of the Trek 520 True Temper tube Frame and fork.  It seemed a shame not to braze a new dropout on.

Now with a  920 56cm frame (and no bike).
For the record:

What fits:
The seat/tube fits, the rear Deore derailleur screws in (not sure if it will reach the 142x12 axle cassette).
The crankset/pedals may be reuseable as it takes a 73mm BB. 
The handlebars, cable brakes, and shifters are bar cons could be reused on an Aheadset stem (supplied).
The rear Trek Rack with some strategic bending can be reused.

What does not fit:
LX Front derailleur (seat tube diam larger)
QR release Wheelset. (Mine were Velocity Chukkers). New Cassette?
Rim Brakes (need cable/hydro Disc).
Need Aheadset stem.
And of course new chain, cables, housing and the little things.

I guess having a Trek may be one advantage of a lifetime warranty. The Surly Disc Truckers only come with a 3 year frame warranty.

[driftlessregion]

Have you considered having it repaired by a competent person?

[natethegreat]

I have been riding for over 40 years, toured a bit, done most of my mechanic work, and have the basic tools.
In general most mods I have done worked,.. a few failed. 
The basement is covered in bike parts since the days of Mafac brakes.
I have built 5 wheels, 1 bike, can tap and mill. Most mods have held up OK.
I thought about frame repair/repaint, but this was what was offered by Trek. 

I considered having the shop do things. The shop wanted me to put the stock 28H wheels of this 920 model (discon) on this bike, (and just reading the reviews of the 920, a few people have had problems with 28H rim spoke design). Even with 32H wheels on my bikes I broke spokes. The shop wanted electronic shifters, and hydraulic brakes. It was pretty clear nobody really toured long distances.

I want to enjoy the scenery, have low maintenance and be mechanically fixable out in the field. A few pounds extra will not kill me by going with more conservative stuff. I always carry multi tools.

We learn   by reading the forums, bike reviews and talking to other experienced wrench friends and posts like this.

If you roll your own, you will be capable of adjusting/fixing most things out on the road. Your bike will be designed as you need it.
Having that competent knowledge is priceless.

[dkoloko]

Much information on that bike here: https://99spokes.com/en-NL/bikes/trek/2019/920

I see no reason not to have hydraulic brakes, as the bike is built for them. 

"It was pretty clear nobody (at the shop) really toured long distances." Not unexpected; what you can find (in my experience) is a shop that knows what is needed from doing work for experienced long distance cyclists. It may be worth shipping your bike to a recommended shop.

[natethegreat]

29er touring tire  suggestions anybody?

OK so the best I could do on the cheap side of this Trek 920 build (avoiding factory 28H wheels) is a  high flange SRAM hubs with Ryde Rival 30 29" Alloy Rims Mountain Disc DW Wheelset. Not much out there in 36Hs for these unless I go custom.

The Ryde website says Rival 30: TIRE WIDTH (MM) 42-64

Does Schwalbe Marathon Greenguards of 700C x 50mm sound OK for these rims?
Schwalbes are nearly flat proof.

I am not sure my newish 700x 37 Schwalbe tires will fit. The rims are hooked and inner width is about 29mm.  I want some suspension I guess, but decent rolling resistance.

Suggestions?

[natethegreat]

In the end Rockville Trek supplied the 920 frame, and even their thru hole front axle did not screw into the 920 fork. I had to bring it in to get retapped.
 
Now the Trek 920 bike is 70% complete. Gargantuan 700x44 tires on Ryde 32H big rims.

In the interim I bought the REI Adventure 1.1 touring bike. Other than 32H wheels I highly recommend this bike. It even came with racks and at 1K was a super deal. Steel is real. Frame made by Giant.