Rail (625Wh) Cracked Rail frames

Juise

New Member
Aug 23, 2022
36
16
Finland
Seen today pics on the fb group, checked mine too (Already going to get replacement because other issue)

The aluminium Rail frame cracks from the lower tube either before or after the battery compartment.

Mine has a crack between the battery compartment near the shock mount. Have you checked yours?

IMG_20220919_203628.jpg

700km, 2021 XL.
 
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Juise

New Member
Aug 23, 2022
36
16
Finland
Quick thinking leads me to the conclusion that the culprit might be the asymmetrical battery compartment slot in the frame.

This design is very demanding structurally to the frame and to design it.

There is always bending in material and this asymmetrical design creates twisting to the down tube. This twisting itself should not be the problem as correct materials can take it to some degree.

Problem in the Rail frame could be that the structure stiffens after the downtube closes up again and the twisting force in the tube ends in short distance, so it creates high stress area where the crack forms.

In english, the battery area bends which makes it twist, and the frame after it doesn't which leads to the material being torn separate - > cracks

EDIT:
This frame problem may be only on some frames, i haven't been able to look from the inside, but someone suggested the motor & shock mount part is a machined part which the downtube joins, so the way (welding settings etc) this joint is manufactured may also contribute to the problem.

I talked to a trek rep yesterday and they were quite confident my replacement frame would not crack, so i think they might have addressed this already in manufacturing or that it was a problem in certain manufacturing batch etc.

Lets see.
 
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Doug Stampfer

Well-known member
Jul 7, 2018
718
731
NZ
This is the first I've heard of it in over 2 years of owning a Rail. I'd say it's an anomaly not like the new Giant reign cracked frames teething problems
 

Juise

New Member
Aug 23, 2022
36
16
Finland
This is the first I've heard of it in over 2 years of owning a Rail. I'd say it's an anomaly not like the new Giant reign cracked frames teething problems

I'm really hoping this is just some rare batch. Some have been driven only 300miles. Mine has done 700km. No huge crashes.

Mainly i just want to point that there might be something in this area, so if People would check their frames, before something bad happens.
It's really hard to see if not looking for it, i had the frame in my shop table when fitting a new shock, in good lighting and still missed it.
 

Kingerz

Active member
Jul 11, 2021
142
103
Australia
Ouch, same as the 2022 Giant issue then. Hopefully Trek acknowledge the problem fast. Looks like the Giant 2023s have a weld back in place over that weak area.
 

Fat Rat

Active member
May 7, 2020
338
167
UK
Ah well Its a bugger but its warrantied so i wont be worrying about it too much
Only small plus is that its not snapping off like my last bike which seemed to give no warning at least the crack is visible first
Just something to check when cleaning down after a ride
And also the fact they may have sorted it and it could have been a batch issue maybe :)
 

Fat Rat

Active member
May 7, 2020
338
167
UK
Ouch, same as the 2022 Giant issue then. Hopefully Trek acknowledge the problem fast. Looks like the Giant 2023s have a weld back in place over that weak area.
Only difference being these are not new frames they came out 2019 so have done a little more work than giants new offering .
 

Jschlueter

Member
Dec 31, 2019
20
9
Bentonville, AR
I had noticed the area looking weird first of the year when I replaced all the pivot bearings. Lately, I hadn't been washing the bike much and wasn't paying attention to it. I've had the bike since 5/20 and have about 5k miles on the frame. Second motor. Seems like two cracks to me. I also broke my Powerfly LT before the Rail. Trek has always taken care of my issues and I absolutely still love the Gen1 Rail!

signal-2022-09-20-10-25-41-331.jpg
 

Fat Rat

Active member
May 7, 2020
338
167
UK
Definitely bring your Rail to your local Trek retailer if you see cracks here so we can evaluate the claim and record the data in addition to replacing this!
Hello
So is it common or rare ?
Come on you know you want to tell all of us loyal customers .
 

Juise

New Member
Aug 23, 2022
36
16
Finland
My replacement frame comes tomorrow so i can
Hello
So is it common or rare ?
Come on you know you want to tell all of us loyal customers .
I'm pretty sure they will not want to tell if it was common 😄

Retail prices would plummet and New onew would stay in the stores.

But it seems their warranty seems to work for now. I'm going to ask for a warranty upgrade to a carbon one if this New one cracks from the same spot.

It looks like there is no weld seam, so the tube is "glued" to the bottom bracket and that seam is giving up on these bikes.
 
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Fat Rat

Active member
May 7, 2020
338
167
UK
My replacement frame comes tomorrow so i can

I'm pretty sure they will not want to tell if it was common 😄

Retail prices would plummet and New onew would stay in the stores.

But it seems their warranty seems to work for now. I'm going to ask for a warranty upgrade to a carbon one of this New one cracks from the same spot.

It looks like there is no weld seam, so the tube is "glued" to the bottom bracket and that seam is giving up on these bikes.
100% agree
Honesty from a manufacturer would be pretty much unheard of no matter what the reason.
My post was more jest than expecting an honest answer, I've been through this before with Orbea and although there warranty process was ok their correspondence was a joke and blatant bull crap.

If they are bonded there, thou maybe that's why some of the battery mounts have been coming unbonded too, crap bond or bonding process which hopefully they have rectified the one or the other or both whichever it maybe 🤞

Ah well keep on riding :)
Enjoy your new frame.
 

Juise

New Member
Aug 23, 2022
36
16
Finland
100% agree
Honesty from a manufacturer would be pretty much unheard of no matter what the reason.
My post was more jest than expecting an honest answer, I've been through this before with Orbea and although there warranty process was ok their correspondence was a joke and blatant bull crap.

If they are bonded there, thou maybe that's why some of the battery mounts have been coming unbonded too, crap bond or bonding process which hopefully they have rectified the one or the other or both whichever it maybe 🤞

Ah well keep on riding :)
Enjoy your new frame.
And for those without warranty some fancy aeromotive riveting is the way to stiching your frames together 😄

I'm guessing the battery compartment tube is some 7xxx series aluminium so it cannot be welded and thats why they bonded it to the bottom bracket. The bottom bracket is welded to the seat stay so thats weldable aluminium.
 

InRustWeTrust

E*POWAH Master
Mar 9, 2020
348
538
Sweden
I had noticed the area looking weird first of the year when I replaced all the pivot bearings. Lately, I hadn't been washing the bike much and wasn't paying attention to it. I've had the bike since 5/20 and have about 5k miles on the frame. Second motor. Seems like two cracks to me. I also broke my Powerfly LT before the Rail. Trek has always taken care of my issues and I absolutely still love the Gen1 Rail!

View attachment 97966


are you sure it's a crack in the frame and not just the paint that has flaked or cracked ?
 

Hornet

Member
Apr 4, 2020
21
12
Slough
I was selling my rail 5 and the buyer noticed the line by the shock, I took it to Trek and they replaced the frame so he was well pleased as m y old frame was scratched and chipped!
 

Fat Rat

Active member
May 7, 2020
338
167
UK
I was selling my rail 5 and the buyer noticed the line by the shock, I took it to Trek and they replaced the frame so he was well pleased as m y old frame was scratched and chipped!
Curiosity
What age and mileage roughly?
 

Doomanic

🛠️Wrecker🛠️
Patreon
Founding Member
Jan 21, 2018
7,546
8,292
UK
Here’s mine, not sure it’s a crack or crap paint. It looks to be lower than all the others on this thread.
E34E4B33-F4BB-4D63-8672-E4B68775B0BC.jpeg
 

Juise

New Member
Aug 23, 2022
36
16
Finland
Anyone with carbon frames?

I presume the structure is the same, the battery compartment tube is bonded to the bottom bracket, but is the bottom bracket in carbon frames carbon or aluminium?
 

Jujujuice

New Member
Jul 14, 2022
42
35
NZ
Anyone with carbon frames?

I presume the structure is the same, the battery compartment tube is bonded to the bottom bracket, but is the bottom bracket in carbon frames carbon or aluminium?
My current 9.8xt carbon frame 2022 does not have it nor did my previous one (2021 model) . My wife's aluminium rail (2022) also does not have it. We have done around 3000kms in total and no issues with any of the frames. I have not heard of anyone else really having it so its just an anomaly and its great trek is replacing the frame for you!
 

Fat Rat

Active member
May 7, 2020
338
167
UK
My mark looks much like Doomanic's. 50 miles on my Rail 7. Lower down than the other pictures. I'll check with Trek to make sure and report back.

View attachment 98861
I've seen that mark before as above as well
It seems like a paint mark or structure mark
Its funny thou as not all of them have it
I have a 22 rail 7 and its smooth there
doesn't mean its any better or worse maybe a different factory , would be nice to know thou .
 

Jschlueter

Member
Dec 31, 2019
20
9
Bentonville, AR
Just an update on my frame. Trek offered me a 9.7 frame for $250. I was told alloy frames would take months to get. I feel like they should send me what they have in stock free of charge but it is what it is. Hopefully they include a matching battery cover but not holding my breath.
 
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