It was two years ago this week when I finished repairing the crank boom on the Quest velomobile. See my blog post of Nov 2, 2013. It turned out that I should have also reinforced the fiberglass where the aluminum connects to it, holding the front end of the crank boom in place.
As you can see in this first photo, the fiberglass has broken and the aluminum support has fallen down into the nose cone.
This second photo shows how the original construction contained two layers of fiberglass, and they were not bonded properly to each other. The two layers have delaminated.
The other side doesn't have two layers of fiberglass. I wonder why not.
Here you can see how the aluminum structure aligns with the fiberglass. I have two spring clips holding the aluminum structure up against the fiberglass. Not really a good match, but that would be because the aluminum crank boom broke at the weld and was re-welded two years ago. I think it came out about one quarter inch shorter than the original, causing this mis-alignment and some fairly ugly matching between the top and bottom fiberglass shells.
This last photo shows how the headlight, mounted on the crank boom, nearly aligns with the hole in the center of the nose cone.
I need to think about how I am going to build up that fiberglass again, without causing additional alignment problems, and correctly locate and drill some new holes for bolting the aluminum to the fiberglass.