Trek OCLV top tube cable guide

thingiverse

This cable guide is a replacement for the top tube cable guides on OCLV carbon fiber frames. This fits all OCLVs with top tubes having a 39mm diameter. It can be attached to the frame using Devcon 5-minute two-part epoxy. One of my OCLV frames is "nude" meaning that it's raw carbon with clear coat on it. This frame has three raw aluminum (likely clear anodized) cable guides on the top tube for the rear brake housing. The first time a guide popped off I freaked out and called Trek tech support and learned that I can reattach the guide using 5-minute epoxy. My other OCLVs are painted in dark blue 5200 (1997) and copper-red 5500 (1994) and use the same cable guides as my 5200 (1996) nude frame. The only difference is the paint - the guides are identical. The paint seems to keep the factory epoxy from failing, while the nude frame repeatedly pop a cable guide every other season. 5-minute epoxy is nice since it doesn't react with the carbon fiber and peels off easily if there's a problem. My sweat corroded the guides on my blue 5200 to the point where the rear brake housing no longer slid or moved through two of the guides. So I masked the guides and cover the rest of the bike with a large garbage bag and used a miniature sand blaster to chase away the corrosion. In the end I repainted the cleaned up guides with RustOleum dark navy blue gloss with a near perfect match. While this was apart I decided to pull dimensions and model a replacement since the corrosion ate some of the aluminum. All of the 1990s OCLV use the same top tube guide, is just a question of raw or painted. Since it's just 5-minute epoxy and the guides are not stressed very much a plastic guide seemed like an obvious thing to have on hand in the future with the benefit that 3D printed plastic wouldn't corrode.