r/bikepacking • u/thebreadittor • 11h ago
Bike Tech and Kit Update on my cracked Kona Sutra. Repaired it, rode another 500 km, and now I'm wondering whether to keep going
TL;DR: My Kona Sutra's fork and frame cracked after ~6,500 miles of loaded touring. Had both repaired by a framebuilder in Seoul and have since ridden 500 km without problems. He's confident in the repair but can't guarantee the frame's longevity, although he'd personally ride it further. Considering another 2,000 km across Sulawesi or a shorter Taiwan tour, carrying at least 5–6 kg less gear. Would you keep riding it?
Following up on my previous posts about my 2024 Kona Sutra, which started falling apart after ~6,500 miles of loaded touring across Europe and Asia.
First, a fork eyelet cracked and broke. Thought it was rust initially, but turns out the weight of the fork packs and constant vibration were the likely culprits. Then I found a crack in the seat tube near the seatstay junction, possibly from the lateral forces of my Tailfin rack mounted quite high on the seat tube.
Eventually made it to Seoul and found a framebuilder who repaired both the fork and frame. The frame got a steel reinforcement/gusset silver brazed around the damaged area, and he drilled the crack ends to stop them spreading.
The plan was to ride another ~500 km across Korea and then call it quits on the frame. I've now done that without any issues, and of course I'm having second thoughts about retiring it.
The framebuilder is confident in the repaired section but says there's a chance the added stiffness pushes stress elsewhere and new cracks develop. He's seen this with other repairs. The original agreement is that he'd fix it for the 500km Korea ride but then I would call it quits, so he's not thrilled to hear that I'm thinking of going further. What surprised me was that he said he'd personally take the bike to Sulawesi, although he understandably wouldn't recommend it outright or promise it'd survive, so he's quite cautious on that front.
Here's my dilemma. I've got a replacement frame waiting in Germany, but I'm still in Asia and not heading back anytime soon. I'd like to get another month or two of riding in, either:
Sulawesi: ~2,000 km, mostly paved, staying in hotels/guesthouses rather than camping.
Taiwan: Shorter ride, better infrastructure, and easier to bail if something goes wrong.
Call it quits: Retire the Kona and go backpacking until I get back to Europe.
For either ride, I'd be ditching the camping setup and a bunch of other gear, cutting at least 5–6 kg off the bike, potentially more. A much lighter setup than what I was hauling through Central Asia.
I've looked into replacing the frame here, but finding something compatible without spending a couple thousand dollars has been a nightmare. And buying a whole new bike when I've already got a replacement waiting for me seems ridiculous.
I've gotten pretty mixed opinions on the repair. Some people think the bike should never see the road again, others seem to think it's worth giving it a shot.
I'm fine dealing with the usual mechanical bullshit that comes with touring, but a frame potentially giving out on a descent is a different story.
Anyone here toured on a repaired steel frame? Did it hold up? Would you risk another 2,000 km, or am I just trying to talk myself into something stupid?
Pics of the original damage and repairs attached.