A disc wheel gives you about 1minute advantage over the bike course of an Olympic triathlon (40km). However, these wheels are very expensive. So I decided to cover the back wheel of my Felt bike with this homemade Depron + self adhesive vinyl film disc. You need for this instructable
- a 1250/800/3mm sheet of Depron; you can use other foams too, but in my opinion Depron offers the best strength to weight ratio.
- self adhesive vinyl film
- thin cable ties
- scissors, screw driver and a knife
Step 1: Cut the Foam Disc
- Cut a disc out of the foam. The disc should be slightly larger than the bike's rim.Remember that you will need to cut a second disc out of the foam sheet.
- Cut a hole in the middle of the foam disc.
- Cut a straight line to the edge of the foam disc.
- Pre-mount the disc on wheel.
- Overlap the foam and mark the overlapping part.
- Cut the overlapping part.
Step 2: Add Adhesive Vinyl Film
- Pre-cut the self adhesive vinyl film. It should be slightly large than the disc foam.
- Put the foam disc on the vinyl film. Apply the vinyl film by removing the paper release liner step by step.
- Put the overhanging vinyl film over the edge of the foam disc and stick it to the back.
- There might be air bubbles. Carefully cut them with a sharp knife to remove the air.
Step 3: Mount the Disc Cover on the Wheel
- Put the cover on the wheel.
- You will need to attach the cover with thin cable ties. Use a screwdriver to make holes in the cover. For each cable tie you will need 2 holes.
- Put the cable tie through the first hole, then behind a spoke and finally through the second hole. I used 6 cable ties per disc.
- Cut the overhanging part of the cable tie.
Step 4: Repeat Step 1 to 3 for the Second Disc
Repeat the steps for the second wheel cover. As this is the side with the sprocket, you will need a larger whole in the middle of the foam disc.
Step 5: Finished!
Now you are ready to go faster! If you like it, feel free to vote for this instructable in the adhesive contest.