Help with installation of ChAero cover on PT wheel

To all,

I just received my new PowerTap wheel last week and trying to fit a ChAero cover on to make a disc wheel that I can race with. I’ve searched this site, wattage topica list, and gordo’s site and tried all tips that I can find but still having problems with the installation.

I’ve trimmed the out surface to fit more flush with the wheel, trimmed the inside hole on the PT hub side and there are still problems. On the PT hub side the cover won’t sit flush with the wheel. In between the screw holes the cover pops up like bubbles or ripples that rub my chainstay and electrical tape won’t make it sit down. On the cog side, the inside of the cover severely rubs on the cassette making alot of friction. Should I cut the hole much bigger so the cassette can sit inside? However, then I’m afraid the cover will come out, over the cassette.

Any suggestions / comments would be greatly appreciated. Thanks in advance.

Rob