Last fall I wrecked a derailer and bent the hanger when I shifted a 
short-cage rear der into the big-big combination. I bought a new derailer 
and aligned the dropout using this 
clever hack (which I could swear I learned of from this 
list): https://youtu.be/TnwreRrorIA

Anyway, it sounds to me like after all these tries that your derailer 
hanger is aligned, and that the problem lies elsewhere. Perhaps a bent cog 
on the cassette? Or the new derailer you're trying has some flaw - e.g. the 
upper pulley can wander? A stiff link in the chain? I can't think of a 
reason that the impact to shifter, cable, and housing would be the issue, 
but maybe there is one I haven't thought of?

"When you have eliminated the impossible, whatever remains – however 
implausible – must be the truth."
-Wes
On Thursday, August 3, 2023 at 6:00:36 AM UTC-7 Bill Schairer wrote:

> I vote for buy a gauge and do it yourself.  I bought a Park DAG years ago 
> after a wreck and have used it many, many times since.  No regrets.  
> Haven't I watched your build videos?  You need this tool regardless.  That 
> said, if a shop used one and aligned the hanger, I have a lot of trouble 
> thinking the hanger is responsible for the jumping. In my experience, a 
> misaligned hanger results in poor shifting, noisy drivetrain, and 
> difficulty adjusting the high and low stops.  If it is jumping between 
> gears, maybe, but then should be happening in all gears or at least never 
> seem quite right no matter which gear?  If it is jumping on the same gear, 
> I'd be thinking chain, cassette and/or chainrings?
>
> Bill S
> San Diego
>
> On Wednesday, August 2, 2023 at 8:20:22 PM UTC-7 eric...@gmail.com wrote:
>
>> Okay, some mild updates. 
>>
>> I've bent and tweaked the hanger with crescent wrenches at least two 
>> dozen times now. Worked on it during the miserable heat wave here and 
>> during nicer weather yesterday. During the process I remove the chain and 
>> the derailer, tweak the hanger, re-install the chain and derailer, test 
>> ride. Repeat. Over and over! Every time I ride the bike the chain skips. 
>>
>> I've tried aligning by hand and eye. I've used a series of straight 
>> edges, trying to reference off the cassette to the face of the derailer 
>> hanger where the derailer sits. I can get the straight edges into plane 
>> with one another but evidently that's not enough because the chain still 
>> jumps. 
>>
>> I feel like I can finesse this thing back into working order but I have 
>> so far been unsuccessful. The hanger is relatively flat considering how 
>> mangled it got. It's considerably better than it was. The bolt hole is 
>> elongated but fortunately derailer bolts screw in nicely and the threads 
>> feel good. Through all my uninstalling/reinstalling the bolts thread in 
>> nicely each time. 
>>
>> One problem is that the guys at the LBS have put their dropout and hanger 
>> alignment tools on the bike and they say the tools show things are aligned. 
>> *But* they are also audibly and visibly weary of putting too much torque 
>> on the hanger and seem to think it's going to shear off the frame if they 
>> look at it funny. I don't think that's going to happen. I talked to Grant 
>> about this twice now and he doesn't think that's going to happen, either. 
>> He shared an acedote wherein he bent a derailer hanger through 180º of 
>> motion several times before the hanger sheared off. I'm not moving mine 
>> nearly as much, just a bit at a time. And today I heard Grant Petersen say 
>> "Steel is magical." So I'm adding that to my lifetime book of memorable 
>> quotes by notable people. 
>>
>> There's another shop in town but I get bad vibes every time I go in there 
>> so I'm going to spare myself and stay away. I know if I go in there it'll 
>> end up being a bad scene and I'll regret it. 
>>
>> I'm open to having a builder try to align the hanger, heat it up and 
>> shape it or braze a new dropout onto the frame. But the builder I know and 
>> have worked with before on three other bikes (this Hillborne included) has 
>> sold his tools and retired. Two other nearby builders haven't returned my 
>> messages. 
>>
>> Now I'm thinking the best next step is to drop > $100 on a derailer 
>> hanger alignment tool and try it myself in the home shop. Looking at the 
>> Park Tool DAG 2.2. This eliminates the hesitancy of other mechanics (I'm 
>> not afraid to wreck the bike) and gives me a useful tool to have forever. 
>>
>> Full options going forward (as I see them, open to suggestions as 
>> always): 
>>
>>    - Buy a gauge and adjust it myself until I'm satisfied or I give up 
>>    and advance to next option
>>    - Take it to a shop
>>       - Go-to shop seems afraid to break my hanger, I don't think that's 
>>       going to happen but they are audibly and visibly weary. 
>>       - Other shop in town I avoid at all costs and don't want to take 
>>       my bikes to them
>>    - Get a new dropout welded onto the bike
>>       - I wouldn't mind doing this but I can't find a builder in my area
>>       - Contacted three people. One retired, the other two haven't 
>>       responded. 
>>    - Send it to Rivendell
>>       - Grant thinks Mark or Antonio can fix the hanger. Cool!
>>       - Grant said to send the bike stripped down, no fork. How are they 
>>       going to align and test it to see if the chain jumps? 
>>       - I don't reaaaally want to freight the bike coast-to-coast twice. 
>>       Not a dealbreaker, tho. 
>>       - Grant said if Mark or Antonio can't get it he knows a builder 
>>       who can do the repair but it could be three months before I get the 
>> bike 
>>       back.
>>       - This leads me back to...
>>    - Buy a gauge and adjust it myself 
>>
>> If you've made it this far, wow, you are invested in this repair! Thanks 
>> for checking in. I'll post more updates as they develop. 
>>
>> On Wednesday, August 2, 2023 at 11:03:10 PM UTC-4 Eric Marth wrote:
>>
>>> Thanks, Ryan. Yes, I think the cost for the repair would be reasonable. 
>>> I worry the cost to freight the frame would be a little painful and the 
>>> time without the bike could be considerable depending on how it shakes out. 
>>>
>>> The poster is the MTB countryside illustration, same illustrator who did 
>>> yours. "Get away fast on a Bridgestone" or something like that. Hills, dirt 
>>> road, country church. 
>>>
>>> On Tuesday, August 1, 2023 at 7:36:10 AM UTC-4 Ryan wrote:
>>>
>>>> Yikes! That is too bad but I'm glad you weren't hurt. I know you are 
>>>> very ingenious, but maybe the frame needs to be sent to Riv for repair? 
>>>> Who 
>>>> will no doubt do the repair at a reasonable cost
>>>>
>>>> Which poster? I have the "saddle up on a bridgestone"...my favorite of 
>>>> the Grant-inspired ones...the one with the rider on a roadbike alongside a 
>>>> galloping horse. Can't remember if I bought it from Rivendell or from a 
>>>> friend of mine who built many of my wheels and at one time was a 
>>>> bridgestone dealer and sold me my 1993 X0-1 that I still have
>>>>
>>>> On Tuesday, August 1, 2023 at 4:55:39 AM UTC-5 R. Alexis wrote:
>>>>
>>>>> That does not look good. Maybe once you get it into a stand and 
>>>>> carefully remove the derailleur and gently realign the hanger you will be 
>>>>> fine. The rear der pully cage can probably be bent back into shape. Issue 
>>>>> is probably trusting it. Hope things work out. Glad you were not hurt. 
>>>>>
>>>>> Thanks,
>>>>>
>>>>> Reginald Alexis
>>>>>
>>>>> On Sunday, July 23, 2023 at 2:13:02 PM UTC-5 eric...@gmail.com wrote:
>>>>>
>>>>>> Hey gang — I was out for a Sunday ride and stopped to take a picture. 
>>>>>> I rolled to the side of the road and did not see the culvert, hidden 
>>>>>> with 
>>>>>> fresh grass clippings. I tumbled over at low speed. I'm fine! 
>>>>>>
>>>>>> When I stood up I noticed my drive-side bar end shifter had rotated 
>>>>>> 90º. And my derailer hanger and the derailer were bent. I spun the crank 
>>>>>> while off the bike and it seemed to move okay so I thought I'd give it a 
>>>>>> go 
>>>>>> as a single speed. 
>>>>>>
>>>>>> I pedaled for a few strokes, then nudged the shifter. It was at that 
>>>>>> time the derailer turned upside down and inside out, bending into the 
>>>>>> spokes and throwing the chain. It was really fun!
>>>>>>
>>>>>> [image: Screenshot 2023-07-23 at 3.05.28 PM.png]
>>>>>>
>>>>>> This is my Hillborne, my most-ridden bike. I'll see if the hanger can 
>>>>>> be bent but I have a feeling it will require some work from a frame 
>>>>>> builder. That's a Suntour Cyclone. Fortunately I have five of them 
>>>>>> (including this one). You might recall the cage tension spring in my 
>>>>>> previous Cyclone recently failed. This is one of the replacements I 
>>>>>> picked 
>>>>>> up. It was in excellent shape but now it's going to the salvage bin. 
>>>>>>
>>>>>> While I was waiting for a ride four people stopped to ask if they 
>>>>>> could help me. One was a cyclist who said "You need anything?" I replied 
>>>>>> "I 
>>>>>> need derailer hanger, a rear mech and a welding torch!"
>>>>>>
>>>>>> Hope your weekend rides weren't so mechanically eventful. 
>>>>>>
>>>>>> Eric
>>>>>>
>>>>>

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