And you think that "1/10th of a millimeter" stress riser you created (which is actually closer to .3 or .4mm deep) is no cause for concern?
12 years in bicycle retail and repair in very busy shops that sold over 1,000 bikes a year and repaired thousands more each year. Another 40 years as a hobbiest with another 700 bikes through the home basement shop and never once have I not been able to remove a seat post with the best tool....common sense.
The mark barely registers as more than a polished mark once you feel about 5mm into the frame, due to the line being so straight it looks like a savage cut but it is really nothing of the sort.
Without wanting to look like I am sticking my chest out here I am intrigued as to what your perfect method of removal is. This came in to me after the customer had already wrenched the head of the seatpost off in a vice, as you can see the gallons of releasing agent that he had soaking in the seat tube for a week before this made no difference whatsoever. Even when this post was cut right through it still had sufficient salt corrosion to have to grip the top and hammer it out. An ultra light cnc'd pin such as this is not sufficiently strong to have an aluminium bar welded on to it and be twisted loose, it would just tear like a piece of orange peel. As it is aluminium on aluminium it cant be melted out with caustic soda. I have used a loctite product in the past which freezes the tubes but results have been mixed, In a commercial workshop it makes no sense to try and ream out the post as it is extremely labour heavy and unless the post is clamped into a jig there is no guarantees that it will cut straight. This little device makes the job far more cost effective to the customer who is paying an hourly rate for the job. I must add that I have never once had a seized post in one of my personal frames, this one lives in the pennines which has savage winters and heavily salted roads.
I would love to hear any other useful tips on the subject if there is something I am missing that eases the burden of this unenviable job I am all ears
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