2007 Trek 1500 Right Chainstay Failed Near Dropout

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2007 Trek 1500 with a right chainstay failure near the dropout after about 2 years of riding. From http://picasaweb.google.com/mlaroche/TheLastYouLlSeeOfMyOldTrek as of 2009/09:

About 30 km in to a multi-day ride, rider noticed a clicking/grinding sound when pedaling with medium effort. Examination by several people revealed no problems, so the rider continued. About 80 km later another person examined the frame and found the chainstay fractured.

Total use about 2,500 to 3,000 km, rider plus gear 95 to 140 kg, mostly rider weight not gear. Most use commuting and light touring, hilly with "sit and spin" rather than "stand and grunt" pedaling style. No off-road use.

Frame and stay are of aluminum. The stay ends somewhat outboard of the dropout, so even without bending loads on the dropout there are bending loads on the stay. That may have contributed to the failure.

Another bicycle was rented for the rest of the ride. A replacement frame was later provided under warranty, with the alternative of applying the non-broken trade-in value of the bicycle to a new bicycle purchase.