For what it's worth, I had a cracked Fisher MTB frame (That's Fisher, not Gary Fisher, Japanese made) that cracked on the seat tube above the top tube weld. 

My brother, who does sign work for a living and is experienced in Aluminum welding was able to repair it for me.  He put a large bead on it, you won't mistake it for OEM, but it's strong and holding fast.

Granted this is a vintage 88 frame and the Al gauge would far exceed a CAAD 7 frame, but he typically welds heavier material and had no problem with this.  It helps if yo have a piece of something similar to practice with.  He had to calibrate his welder using some sheet Al of similar gauge.

I'm also thinking that he used a MIG setup, not a TIG (technically its Gas Tungsten Arc Welding GTAW).

Anyway, he can't hep you here, because he's not in town, but you should be able to find someone, though I can't say what they will charge.

I didn't have luck with it, but you could give adhesives a try first, if you can't find an bargain welder.  Maybe a glob of JB-Weld?

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To: osucyclingclub@yahoogroups.com; columbuscross@yahoogroups.com; teamawesomecycling@yahoogroups.com
From: kieran.sikdar@...
Date: Mon, 2 Jun 2008 12:08:12 -0400
Subject: [columbuscross] cracked cannondale frame

I have an aluminum cannondale caad7 frame sitting in my basement that I'd like to put to good use.  I don't know exactly what that means because it has a small crack in the top tube from a crash and is most likely not suitable for riding/racing.  Does anyone have a good recommendation for what to do with the frame?  It's really high quality metal and it seems like it would be a shame just to toss it in the recycling.  Any suggestions?

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