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"I build me a disc" DIY Aero Wheel
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That title is from youtube, where a Deutsche? kid built an aero wheel. I thought that was pretty cool so with a orphan rear wheel I decided to build me a clincher disc. It's kind of a Zipp - HED hybrid ... Zipp uses a foam core, and HEDs are covers over the base Alu rim. This is both an alu rim and foam core.

OK so step one was to prep the wheel and douse the inside area with PU foam to support the outer layer. I had my doubts with the foam application but it turned out promising. Today we shave the expanded foam and sand it smooth, and then decide what to do next. It would be possible to actually just use a xx mil adhesive vinyl if the foam is smooth enough. If not I have 2x2 twill I can use but that will impact weight and make the thing stiff as blazes.



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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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Clear iron-on Monokote.

Less is more.
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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Don't forget to leave a hole for your air valve lol the kid in the video didn't have one I think. And that could eventually be problematic ;)
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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Interesting (but simple) approach.

Got a link to the video?, that would be cool to see.

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Re: "I build me a disc" DIY Aero Wheel [DarkSpeedWorks] [ In reply to ]
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Here it is the official I build me a disc


I have yet to look at the depron instulation, don't know what that material is.


Weight of course is a concern, the foam is pretty light density, but adds maybe 250g's



<https://www.youtube.com/watch?v=SAAEze4nMyE


Training Tweets: https://twitter.com/Jagersport_com
FM Sports: http://fluidmotionsports.com
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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Interesting dual layer approach.

But the music on the video kinda drives one crazy.

Advanced Aero TopTube Storage for Road, Gravel, & Tri...ZeroSlip & Direct-mount, made in the USA.
DarkSpeedWorks.com.....Reviews.....Insta.....Facebook

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Re: "I build me a disc" DIY Aero Wheel [DarkSpeedWorks] [ In reply to ]
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DarkSpeedWorks wrote:
Interesting dual layer approach.

But the music on the video kinda drives one crazy.

For anyone watching the youtube...feel free to mute. There is no speaking or otherwise useful info that you'd miss. :)
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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What is the purpose of the foam if you're just covering the rim/spokes anyway?

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Re: "I build me a disc" DIY Aero Wheel [dfroelich] [ In reply to ]
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+1 on the mute (Skrillex not my thing)

I am sorry if this is a stupid question... but is this any faster than a wheel cover?

Aren't high end disk wheels faceted to improve is low yaw wind conditions?

I do the same thing as them, just slower
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Re: "I build me a disc" DIY Aero Wheel [snackchair] [ In reply to ]
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snackchair wrote:
What is the purpose of the foam if you're just covering the rim/spokes anyway?

If it produces the "whomp whomp" sound, then I would find it worthwhile.
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Re: "I build me a disc" DIY Aero Wheel [matt_cycles] [ In reply to ]
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+1
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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The Zipp stickers are a nice touch.
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Re: "I build me a disc" DIY Aero Wheel [matt_cycles] [ In reply to ]
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matt_cycles wrote:
snackchair wrote:
What is the purpose of the foam if you're just covering the rim/spokes anyway?

If it produces the "whomp whomp" sound, then I would find it worthwhile.

+1

Totally worth it to get the whomp sound.
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Re: "I build me a disc" DIY Aero Wheel [blueapplepaste] [ In reply to ]
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These guys found the whomp whomp sound. https://www.youtube.com/watch?v=rbvxlvSIIww

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Re: "I build me a disc" DIY Aero Wheel [texafornia] [ In reply to ]
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Whomp whomp is good...and you know she drums like that already... stoked about the weight. After going at it with a watermelon knife, body file, and sander I tipped the scales at under 1100g.

I drove into town on my way to get beer and smokes, looked for some sandable sheet "instulation". Nothing suitable. I wanted a spreadable filler, super light. So I made a water-based mixture using some superlight West filler I had in the shop. Binder, fillers - hope it works! 24 hours to set up before sanding, which should be super easy to do. Why foam? As it expanded, the foam is very, very light. No real structure is necessary, just resistance to blowing out of the spokes. A foam core with a thin vinyl covering should be the lightest possible setup.






Training Tweets: https://twitter.com/Jagersport_com
FM Sports: http://fluidmotionsports.com
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Re: "I build me a disc" DIY Aero Wheel [blueapplepaste] [ In reply to ]
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I've been making DIY discs from spoked wheels for a while. If you use spray foam insulation to
bond a DIY ABS cover to a wheel it'll do just about as good as far as producing the ominous sound that
an actual disc makes.

I have never gone as far as completely filling in the wheel with spray foam though. What I do is spray it
and smooth it out on both the spokes and the inside of the cover then let it cure for a day or two with some weight added
to the wheel to keep it from expanding.

I'll make one later in April and plan on then having the ABS cover wrapped in diamond plate look car wrap, maybe something
like this.. http://www.ebay.com/...7?lpid=82&chn=ps

Find out what it is in life that you don't do well, then don't
do that thing.
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Re: "I build me a disc" DIY Aero Wheel [pattersonpaul] [ In reply to ]
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Any type of plastic or sheeting of thickness 1/16" or more will be too heavy. ABS or HDPE for example - I have both in the shop, too low tech! You won't see that on aircraft/RC builds.

The wheel builder covers are like 400- 500 grams

The PU foam was really nothing - under 100 grams. I made an error on the filler for fairing in.

This morning on my way to cigarettes and coffee, I got some lightweight spackle and also latex foam. Used some of the both to clean things up. It's setting up right now.

I also scored some awesome Carbon fiber wrap at Walmart of all places. So should be complete in 24 hours.

Training Tweets: https://twitter.com/Jagersport_com
FM Sports: http://fluidmotionsports.com
Last edited by: SharkFM: Apr 8, 15 14:35
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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I think the guy in the video use the foam sheet on top because he couldn't get the sprayed foam smooth enough.

What does the carbon tape weigh?
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Re: "I build me a disc" DIY Aero Wheel [rruff] [ In reply to ]
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She'd done. The lightweight spackle filler worked well. I only sanded one round so it's a bit lumpy but at 1300g weight is half decent. The wraptech covering is nice to work with but real carbon would have been cool, if using a thin fabric, no need to beef it up. PIA project. I think a better approach might be to start with a really light wheel (eg 750g) and use Balsa sheet on each side before using a real carbon covering.Probably get to the 1000g figure.



Training Tweets: https://twitter.com/Jagersport_com
FM Sports: http://fluidmotionsports.com
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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That looks pretty cool, but I don't think I'll try to replicate it. I need the cover to be removable.

I found that you can buy pvc foamboard in 1mm thickness, but white only. It's half the weight of solid PVC and should be stiff enough, and then a layer of wrap. This would be similar to removable plastic covers, nothing like yours.

According to the specs I found, both sides should weigh ~470g (380 for the sheets and 90 for the wrap), so it adds a little over 1lb to the weight of the wheel.
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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Hm. This is actually pretty cool. What was the drawback to using standard spray foam from the start?

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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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Do you make some kind of a mold or backing to keep the foam in place while it hardens, or does it just stay where you spray it?
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Re: "I build me a disc" DIY Aero Wheel [Rambler] [ In reply to ]
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The wheel I started with is reasonably light, made by XERO. Might be cheap Alum never did brake that well actually. The front of the set was wrecked in a crash. So good to experiment with. I have been wanting a clincher disc, and the older used HEDs looked really heavy/funky.

I used a tubie tire and some clear poly. I had to use 2 full cans. As the foam setup I removed the poly - it will expand and cure better with air both sides.

Foam $15
Spackle $10
Carbon Wrap $60
I bought a 1/3 sheet sander too

The problem with the foam work is that it is not deterministic. It's up to the PU foam gods as to how it turns out. The featherweight spackle is trick from the model airplane wing guys, and saved the project. Lightweight spackle is a latex based, with super light filler, so easy to work with and sand etc. Even so the spackle added 150-200 g's straight up! I had to use the whole tub, and it was a good sized tub.

I have to weigh the whole deal now, with tire, etc.

HED Jet 9 clincher all in is 1550 gms * story about this wheelset.
Zipp Tubie 900 Disc all in is 1500
Gipemme (sp?) Aero/Deep Alum wheel 1750 gms
Shimano C50 Tubular - will be lightest of the lot.

The HED wheelset/disc combo is actually for the GURU build, still in the works. I got these baby blue Michlens on special, and that rear tire is painted :O - paint color is perfect, but adhesion didn't work!!

Edit - I rode it like 500meters last night, it makes the WHOMP WHOMP sound 100% just like the Zipp. Will give it a shakedown today - in the rain

Training Tweets: https://twitter.com/Jagersport_com
FM Sports: http://fluidmotionsports.com
Last edited by: SharkFM: Apr 10, 15 10:33
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Re: "I build me a disc" DIY Aero Wheel [SharkFM] [ In reply to ]
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SharkFM wrote:
Edit - I rode it like 500meters last night, it makes the WHOMP WHOMP sound 100% just like the Zipp. Will give it a shakedown today - in the rain

You are my new idol. As a fellow DIY-er and anti-bikesnob, I cheer you on sir. God speed!
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Re: "I build me a disc" DIY Aero Wheel [MrPinochio] [ In reply to ]
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I love seeing DIY and creative bikes on the road. Some of the most basic are the coolest. e.g. a bull horn fixie, leather saddle, vintage racing wheels. I think it might be a good idea to ride a fixie on a regular basis as a rehab cycle.

Yeah to be honest, in my mind I thought this was a borderline $hit project... but one ride changed all that. Just got back from ripping it up: the DIY disc is fantastic. For sure outperforms my Zipp! Mostly it feels like a "wheel", and a good one at that. The DIY disc powers (accelerates) up seamlessly, way better than when it was - a cheap wheel, because it's stiffer now and whomp whomp whomp carries speed like none other too. Perfect match for a HED Jet6, which does the same thing - behaves like a good wheel should.

Tire has got to go. Warning about the Mavic Yksium comp - they are horrible in the wet & cold. This is a stock Cervelo tire. I got off these ASAP in Dec, had them sitting around.

I'll see if I can shoot an onboard video this weekend.

Training Tweets: https://twitter.com/Jagersport_com
FM Sports: http://fluidmotionsports.com
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