DIY Berk saddle repair
Moderator: robbosmans
I've spent the past 5 months trying unsuccessfully to get a Berk Lukna saddle repaired due to what I presume are COVID-related shipping issues. I shipped via USPS, the package made it to Slovenia and for unknown reasons was rejected by Sovenia customs and returned to me. After I got it back, I re-shipped it the following day back in Oct . . . still waiting for it to make it through Slovenia customs. Maybe I'll get the saddle back some time in 2021.
Now I'm down to just my Lupina. And let me tell you, when I heard the "pop" and felt the Lupina give a bit more than usual, I was NOT happy about having to ship it to Berk and be without my only two Berk saddles for who knows how long. So I took matters into my own hands.
Went to the local hardware store and found this epoxy: I didn't take a picture of the packaging, but an application specifically listed was carbon fiber composite. Unfortunately they didn't have black color available.
I removed excess original epoxy and lightly sanded the rail support area and saddle shell. Applied epoxy and clamped like so: End result: I've put 400 miles on the saddle since this repair, riding the same roads, and the repair shows no signs of failing. The epoxy has a bond strength of 3770 PSI (265 kg per square cm), which I figure should be good enough for my 88kg weight. So if your Berk saddle fails and you don't feel like being without it for months on end, this is how to repair it yourself. Hopefully once this pandemic winds down and shipping returns to normal repair wait times will be less of a factor.
Now I'm down to just my Lupina. And let me tell you, when I heard the "pop" and felt the Lupina give a bit more than usual, I was NOT happy about having to ship it to Berk and be without my only two Berk saddles for who knows how long. So I took matters into my own hands.
Went to the local hardware store and found this epoxy: I didn't take a picture of the packaging, but an application specifically listed was carbon fiber composite. Unfortunately they didn't have black color available.
I removed excess original epoxy and lightly sanded the rail support area and saddle shell. Applied epoxy and clamped like so: End result: I've put 400 miles on the saddle since this repair, riding the same roads, and the repair shows no signs of failing. The epoxy has a bond strength of 3770 PSI (265 kg per square cm), which I figure should be good enough for my 88kg weight. So if your Berk saddle fails and you don't feel like being without it for months on end, this is how to repair it yourself. Hopefully once this pandemic winds down and shipping returns to normal repair wait times will be less of a factor.
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yes that works.. eventually you might have to do it again ( I did ) Mine is on the gravel rig.. so it sees rough terrian.
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There's a company named epocast that makes a bunch of carbon specific epoxies that are designed to repair aerospace composites. The stuff is FAA approved and very good, if a bit pricy-like $35 for a dual syringe that needs a standard epoxy plunger or gun.
I love Jure's stuff, have a bike of his,and just repaired a saddle for my own use (given to me by a forumite in exchange for repairing a slightly dinged Lightweight). He's on the cutting edge, but stray's over just a bit. The saddle shell is so flexy (which makes it both light and comfortable) that a bond in that area is very highly stressed.
I love Jure's stuff, have a bike of his,and just repaired a saddle for my own use (given to me by a forumite in exchange for repairing a slightly dinged Lightweight). He's on the cutting edge, but stray's over just a bit. The saddle shell is so flexy (which makes it both light and comfortable) that a bond in that area is very highly stressed.
Cysco Ti custom Campy SR mechanical (6.9);Berk custom (5.6); Serotta Ottrott(6. ; Anvil Custom steel Etap;1996 Colnago Technos Record
There's a difference between poor engineering and cutting edge. Ax Lightness is cutting edge and at risk of breaking. When a large number of saddles are breaking due to a comical bonding method, Berk is the former.glepore wrote: He's on the cutting edge, but stray's over just a bit.
Sorry people, but there's a certain point where we need to stop giving the benefit of the doubt and hold someone to a higher standard. It's well documented his products are flawed...
Assuming he didn't already, maybe @RNAV's saddles (good job, BTW) are older revisions, but only Jure himself can tell. Unless you have a full picture it's hard to tell, a bit more publicity might help Berk reputation-wise. This is the same stuff as software bugs or car part recalls.
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I dont understand. If what is required is a simple bond, what is the method being used on manufacture that is less reliable? It can't be that the bond is weak because of a weight cost or cost of goods: surely?
my guess is the material used by berk is either too brittle or maybe not cured properly. I've had 3 failures.. finally I just got tired of the replacements and just keep one and JB-welded it.ghisallo2003 wrote: ↑Tue Dec 15, 2020 5:22 pmI dont understand. If what is required is a simple bond, what is the method being used on manufacture that is less reliable? It can't be that the bond is weak because of a weight cost or cost of goods: surely?
2024 BMC TeamMachine R
2018 BMC TImeMachine Road
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2002 Moots Compact-SL
2019 Parlee Z0XD - "classified"
2023 Pivot E-Vault
I think glepore nailed it above: "The saddle shell is so flexy (which makes it both light and comfortable) that a bond in that area is very highly stressed."spdntrxi wrote: ↑Tue Dec 15, 2020 5:28 pmmy guess is the material used by berk is either too brittle or maybe not cured properly. I've had 3 failures.. finally I just got tired of the replacements and just keep one and JB-welded it.ghisallo2003 wrote: ↑Tue Dec 15, 2020 5:22 pmI dont understand. If what is required is a simple bond, what is the method being used on manufacture that is less reliable? It can't be that the bond is weak because of a weight cost or cost of goods: surely?
Maybe a redesign of the saddle shell / rail interface would help.
No kidding !
Just reading this short thread there are at least 5-6 failures
For these prices??
At some point a simple photo to Berk should suffice & new saddle on priority delivery period
Along with a post paid return box for broken item if he wants it back
If not forget it
That is or atleast for me the routine... actually less then that.flying wrote: ↑Tue Dec 15, 2020 10:23 pmNo kidding !
Just reading this short thread there are at least 5-6 failures
For these prices??
At some point a simple photo to Berk should suffice & new saddle on priority delivery period
Along with a post paid return box for broken item if he wants it back
If not forget it
Email a picture..
new saddle gets sent
you even keep the old one.
The last saddle that broke for me, I just repaired myself much like the op and just sold the new replacement online to wash my hands of the whole thing. Eventually if this one keeps rebreaking, I will just bin it.
2024 BMC TeamMachine R
2018 BMC TImeMachine Road
2002 Moots Compact-SL
2019 Parlee Z0XD - "classified"
2023 Pivot E-Vault
2018 BMC TImeMachine Road
2002 Moots Compact-SL
2019 Parlee Z0XD - "classified"
2023 Pivot E-Vault
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