Too bad your frame isn’t steel. You would have better luck fixing it. My shop just stuck a reamer (without the cutter) in and it reshaped the tube. Yours isn’t going to be as simple.
“A new frame is out of the question right now.”
That’s too bad. Is it even possible/desireable to replace a tube on an Al bike? Definitely not a DIY job in my opinion. So if Cervelo can’t help out, I’d go the local builder route. Once (if) you get it fixed and painted, I assume you’d be in close to the same cash terrirory as a new well priced frame (no fork).
There are speciality bike shops that advertise aluminium frame repair. Do a google on the net and you may find one near you.
DIY won’t do it.
I concur with everyone else- it will cost almost as much to replace the headtube and repaint. Your paint will be burnt up from welding.
Sorry dude, it’s toast.
My old (first generation) Elite T-6 developed a small crack in the head tube. Dave Greenfield was able to send it to his builder and have the frame cut apart, rewelded with a stronger head tube and repainted. Cost was almost as much as the frame was worth so it’s borderline as to whether it’s worth it. I think you are out one frame unfortunately.
Ok not a bike mechanic at all but I am involved in manufacturing.
Why would you replace the headtube? Maybe I’m wrong but couldn’t you just machine out the area a bit larger and press in or loctite in a sleeve and remachine?
Cutting, welding etc will as others have pointed out, fry the paint as well as throw stresses into the frame and probably cause more issues. Simply machining and inserting a sleeve and remachining would seem tp be the way to go. This is assuming that there is suffiecien meat to do that, which may not be the case. Like I said not a bike mechanic.
Then again I’m guessing unless you have some friends that are decent machinest…it’ll cost you as much as a new frame to do that.
~Matt