Riser for Bicycle Aero Bars 2

[Don52]

Back in April I designed and built a riser for my aerobars to create a more comfortable position for my forearms while using the aero bars on my mountain bicycle. Here is a link to the post.

https://weldingweb.com/vbb/threads/7...ycle-Aero-Bars

The following is a picture of the aero bars with the riser as well as a close-up picture.

1. Original aero bar close up


2. Original aero bar


One comment from Rexcormack on the welding web forum got me thinking:


“Re: Riser for Bicycle Aero Bars

Nice job but keep an eye on those fasteners at the bottom.
That will be your weak link because of the leverage those risers will have!”

As a result of the comment, I decided to add a diagonal brace to each riser to minimize the stress on the two M6 screws. The design is shown below.

3. New diagonal brace


The first step was coping the diagonal brace tube.

4. Setup for coping tube


5. Coping setup close up

[Don52]

And here are the tubes all done.

6. Tubes all done


To make the feet I cut out the drawing of the feet and glued the drawing to a piece of aluminum.

7. Cutting out feet


The cost of the original aero bar assembly was $21, so I purchased a second assembly just for the clamps. I can’t manually machine a clamp for $10.50. I removed the excess material from the clamps.

8. Cut down clamp


Notice the cross hatched pattern indicating that the head of my Bridgeport is properly trammed in.

9. Cross hatched finish


Here are a couple of close-up pictures of the welds.

10. Weld 1

[Don52]

11. Weld 2


12. Weld 3


And here are two pictures of the aerobars with the diagonal brace in place.

13. Close up of diagonal brace


14. All done


One thing that I like about this forum is comments tha t if taken improve the design or at least the next design.


-Don