Low Cost Aerobar Upgrade Kit
Designed by Otis Hatfield
Version 1.0
Cycling is a technical sport, it is contingent on equipment for participation. The sport has matured over the past hundred and fifty years in every way. On the final day of the 1989 Tour de France, Greg LeMond posted a time 58 seconds faster than race leader Lauraunt Fignon. This margin of victory pushed Fignon out of the Yellow Jersey by just 8 seconds (the smallest margin of victory in Men's Tour de France history). Stage 21 of the 1989 TdF was a Time Trial and what made Greg LeMond's run curious is that he had installed a set of Scott handlebar extensions to his Mavic "Bullhorn" Time Trial handlebar. While known amongst Triathaletes this was a first use in major competition. From this point, and with the blessing of the UCI, the "Aerobar" became an essential piece of equipment in races against the clock. Its use quickly became ubiquitous in Road Time Trials and the track events Pursuit, and Kilometer.
Original models were simple and inexpensive to install. Riders make a simple change to bike fit and a bolt on extension was all that was necessary. Much like everything in the sport of cycling, that has since signficiantly evolved. Bespoke and highly specific Time Trial bikes now dominate higher level competitions where allowed. An additional TT bike or even a spare set of handlebars for a track bike can be extremely limiting to amateurs, juniors, and under-funded national federations.
There is much discussion over how best to make the sport more approachable, mostly concerning banning specific equipment at certain competitions. The Canadian cycling federation has banned TT bikes from their Junior National championship. I believe this is a mistake. TT bars aren't, and at this point shouldn't, go anywhere. Ultimately they're just a pair of aluminum tubes bolted with brackets to other aluminum tubes. While better versions exist there is absolutely a way to get performance out of lower cost, or even recycled, equipment. The question shouldn't be what type of equipment do we ban, but rather what cost cap should we implement and how will we enforce it. When more money is allowed to be spent, it will be, no matter what the equipment restrictions are.
The following is a low cost adjustable kit designed to convert cheap and standardized 22.2 L-Shaped aerobar extensions to a more modern position. The goal is to recycle existing components often found in the bins of a local bike co-op into something you can compete with at local Time Trials, Triathlons, Pursuits, and Kilos.
The primary recommended printed material is ASA. The parts are designed to be printed with very thick walls and I have had luck with some parts printed in PLA, ASA is recommended due to its UV-Resistant properties. The whole kit is about half a spool to print. Brass inserts are inserted via a soldering iron and forearm gap fillers are kept in line via 2x 4mm aluminium rods.
This is my first try, I implore people to steal this idea. Modify it, sell it (with attribution), do better than me at the engineering. Build these and go do a local TT. How far can we go with as little as possible.
If you want Fusion files, etc just hit me up on the contact button and I'll get back to you. For now im hosting files on Printables.
Original models were simple and inexpensive to install. Riders make a simple change to bike fit and a bolt on extension was all that was necessary. Much like everything in the sport of cycling, that has since signficiantly evolved. Bespoke and highly specific Time Trial bikes now dominate higher level competitions where allowed. An additional TT bike or even a spare set of handlebars for a track bike can be extremely limiting to amateurs, juniors, and under-funded national federations.
There is much discussion over how best to make the sport more approachable, mostly concerning banning specific equipment at certain competitions. The Canadian cycling federation has banned TT bikes from their Junior National championship. I believe this is a mistake. TT bars aren't, and at this point shouldn't, go anywhere. Ultimately they're just a pair of aluminum tubes bolted with brackets to other aluminum tubes. While better versions exist there is absolutely a way to get performance out of lower cost, or even recycled, equipment. The question shouldn't be what type of equipment do we ban, but rather what cost cap should we implement and how will we enforce it. When more money is allowed to be spent, it will be, no matter what the equipment restrictions are.
The following is a low cost adjustable kit designed to convert cheap and standardized 22.2 L-Shaped aerobar extensions to a more modern position. The goal is to recycle existing components often found in the bins of a local bike co-op into something you can compete with at local Time Trials, Triathlons, Pursuits, and Kilos.
The primary recommended printed material is ASA. The parts are designed to be printed with very thick walls and I have had luck with some parts printed in PLA, ASA is recommended due to its UV-Resistant properties. The whole kit is about half a spool to print. Brass inserts are inserted via a soldering iron and forearm gap fillers are kept in line via 2x 4mm aluminium rods.
This is my first try, I implore people to steal this idea. Modify it, sell it (with attribution), do better than me at the engineering. Build these and go do a local TT. How far can we go with as little as possible.
If you want Fusion files, etc just hit me up on the contact button and I'll get back to you. For now im hosting files on Printables.
