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Old Today, 12:04 AM   #17 (permalink)
Grant-53
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Join Date: Feb 2010
Location: Elmira, NY
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I made my aero bars using a pair of end bar grips, four 300 mm pieces aluminum 25 mm angle stock, and two pieces of 22 mm tubing 100mm long. Bond the aluminum angle stock to form a T shape with the lengths offset about 25 mm. Drill two 6 mm holes through both the bar end and the angle pieces. Notch the 22 mm tube so it fits flat against the longer of the T pieces. Assemble with 6 mm bolts and nuts. Attach to a flat handle bar 125 mm either side of the stem. Adjust so your elbow should rest comfortably. Put grips on the vertical tubes andany cushioning on the top of the T sections.

A small front fairing cut from a piece of corrugated plastic 600 mm by 900 mm. Cut slits toward the center in a radial pattern. Overlap at each cut about 30 to 40 mm to form a concave shape. Secure by punching holes through both layers in pairs 25 mm apart and thread small zip ties. Mount a length of angle stock to the head tube with a muffler clamp. Attach the concave piece to the angle boom and cross brace with pieces of cord attached to the top corners.

The tail section is a 900 mm cone of sheet material that tapers from the hips to a point. Mount to an aluminum angle piece clamped to the seat tube. Hoops of plastic tubing can be used inside the cone to maintain the shape if needed. See the photos of the Rocket tailpiece by Oscar Egg

A wheel cover disc is safe to use only on the rear wheel. ANY FAIRING MUST BE ATTACHED TO THE FRAME AND NOT THE STEERING COMPONENTS. This will prevent crosswinds from affecting the steering control.

Last edited by Grant-53; Today at 12:05 AM.. Reason: Addition
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