Trek 83663-1 Frame Protect - Bottom Bracket washer

thingiverse

This vital 0.5mm thick washer with a diameter of 54mm outside and 35mm inside has saved my 1994 Trek OCLV 5500 frame from certain destruction by the chain. In the process, it sacrificed itself and will not be able to save the frame again. Unfortunately, Trek discontinued stocking this part and they have become extremely difficult to find. I was able to take precise measurements from a new part and happily share the information so that others may locate it, or have a replacement made in the future. The easiest way to produce this is by using a laser or abrasive-water-jet cutting company and make it out of stainless steel. I have provided this in DWG, SLDPRT, and STL formats. This part needs to be made from corrosion-resistant metal. The STL model is just provided because Thingiverse is a 3D printing site. Plastics will not work for obvious reasons and would also likely cause the bottom bracket fixed cup to come loose during a ride... too squishy. At least the next person who might need this won't have to search for specs. The attached Word doc file provides some history about the OCLV frames and how this part came to be created. Single part custom laser cutting is expensive. You pay dearly for the initial setup. You would be lucky to pay under US$30 for one piece around US$40 for ten pieces. It is however worth a try to walk into a local waterjet or laser cutting house and see if they'd take pity or combine it with an upcoming job. In case it comes up, the part number for the bottom bracket cable guide is 745889418835 - This is the wire guide and some versions have more closure around the wires to prevent them from jumping off and running against the painted carbon. These are even harder to find than the washer in this posting.