Look frame - torn off derailleur hanger

We have a totally buggered Look frame. The carbon part, into which the aluminium derailleur hanger is bolted, has ripped clean off.

There is no chance of getting a fix done professionally or a warranty replacement, as we're in Rwanda. We do have some epoxy, some carbon fibre sheet material, a fully equipped bike workshop (including a hanger alignment tool plus a drill and some taps) and access to a pretty good engineering workshop in the capital. We've done some carbon repair before but not faced this exact problem. Anyone got any bright ideas?

Trying to post photos but having difficulties... Bear with...

maybe something like this? http://www.ghost-bikes.com/uploads/RTEmagicC_x12.png.png a simpler version but I'm guessing you'd have to custom make it......

Maybe try sandwich what remains of the existing dropout with something like 1mm stainless steel. Shape this to the internal curve of the dropout, secure with epoxy and maybe 1mm pins peened over, perhaps countersink the pin holes to accept the peened over head thus giving a flat surface.
Extend this to the shape of the broken extension.
Epoxy and pin the broken off part between the sandwich.

@Sam_Doman knows his way around a carbon repair...

What freezing77 said.

Another option is a "Wheels Manufacturing emergency gear hanger" similar to the linked ghost hanger above, these come in around 4 - 4.2mm thick alu and simply slip over the axle hole and are held in place by the Q/R nut, you might need a longer skewer. The downside is when you remove the rear wheel the hanger&mech drops free too, but it could be worth looking into.

I have used one with a 10mm bolt through axle, when set and in place, brilliant, 3 hands while setting up would be nice but i managed ok. Gear shifting seemed fine when taking a wheel off and back on again, indexing stayed put.

Thanks all for your helpful input. I like the suggestion from freezing77, and will do something like that in due course.

For now I've used a Wheels Manufacturing emergency gear hanger. It works for now, but I dread the next puncture!

It will keep you rolling :)

Did you retain full spread of gears ?
For others reading, using the hanger offsets the mech so if you just put it on as a fast fix you have to be carefull with shifting until you reset the mech travel stop screws, from memory until you reset i lost 1&2 gear and had to stop at 7th as due to offset it was in 9th, trying to select 8th would drop the chain/overshift off the cassette. Once recalibrated the full use of normal gear range returned.

No science to back this up....... you might find/notice slightly sharper shifting as the Wheels Mfg hanger is stiffer than normal hangers which are designed to bend and break.
Excuse the questions, apart from chatting with Wheels Mfg at a trade show your the first person i know who has used one in the field so to speak.

I did practice rear wheel changes, after several goes i was able to reset fine on my own, can't say it took much longer. First couple of goes a third hand would have been nice, but soon got round that, so don't worry about punctures.

After mounting and clamping with QR skewer, the Wheels MFG hanger took a little bending before it was aligned to be planar with the sprockets. Probably because the dropout was not in great shape.

Didn't lose any gears! Rear derailleur got pushed outboard maybe 5-8mm, so chucked the limits right in, worked a charm. This will obviously be different with all different dropouts of different thicknesses.

I won't be riding it, it'll be a young Ethiopian rider. They will have a very fun half an hour if they puncture.

It's not a 586 is it? My good bike is a 586 and I've heard bad things about the mech hanger...

Also, as a metal worker (not carbon repair expert though) I'd avoid trying to glue metal. It never really works.

It's a 595. Perhaps many models have delicate hangers?

I have before glued together strips of steel and aluminium using epoxy. They seemed pretty secure but I didn't cycle them through temperature changes so can't be sure. It's probably a case by case type thing.

In the MTb world you can get bolt on mechs . Look at shimano hone . So mech bolts to end of axle . Means new wheel , and will never really match bike. I have a new rear mech you can have , question mark on postage to Rwanda though . Current fix looks good , maybe put a resealing tube in that back wheel to reduce punctures..

i remember seeing a post about it here
http://www.carbonbikerepair.co.uk/page/2
rob's a nice guy and experienced with hi-end frames. maybe he wouldn't mind giving advice.
rob@carbonbikerepair.co.uk