Trek 83663-1 Frame Protect - Bottom Bracket washer

thingiverse

This large 0.5mm thick washer with an outside diameter of 54mm and an inside diameter of 35mm just saved my 1994 Trek OCLV 5500 frame from being chewed by the chain. In the process, it gave its life and will not function to save the frame again. Sadly, Trek discontinued stocking this part and they have become nearly impossible to find. I was able to take accurate measurements from a new part and happily share the information so that others may find it, or have a replacement made in the future. The easiest way to have this made is using a laser, or abrasive-water-jet cutting company and have this made from stainless steel. I have provided this in DWG, SLDPRT, and STL formats. This part wants to be made of metal that is corrosion resistant. 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 a bottom bracket fixed cup to come loose during a ride... just too squishy. At least the next person who might need this won't have to hunt for specs. The attached Word doc file provides some of the history for the OCLV frames and how this part came to be. Single part custom laser cutting is costly. 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. BTW - 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.