Aero Gusset • Flange • Webbing Appreciation

Dig it

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What is that? It looks like the one in anti porn.
Tis epic

Nice... Inspiration for the aero future incarnation of my GT "current project" which you have helpfully been commenting on?? (much appreciated btw!)

It is supposedly 'homemade'. Would like to know how that happens. Looks like a machine IMO.

It's a round tubed steel frame with some home beaten steel aeros added. Must weigh a ton.

Only pros need worry with weight. Long as I'm crushing beers and burittos I'm down with it!

How do they beat the steel aeros to such perfection.
And the aeros gain and the radness gain is equal to the weight.

Don't know how they built it but I have had an idea kicking around about I would do it if I can find someone to build the base metal structure and gain some motivation haha

And what would that idea consist of?

Bonded composition fairings...

I wont pretend I know anyting about what that is and google want much help.

There was a guy on here who did his own flanges. (here)

Where is that last photo from? your own handiwork @HHC ?

Ha, I wish. I beleive it was found by @kenzo on reddit here.
If you're asking to gather details of the flange manking process for your GT then I'd look here. I think it bascially consists of adding filler to (existing) thin metal flanges.
I think @young_gun had an idea of how the picture above was done though bear in mind that it would make it super heavy.

Thanks! I have looked through @monoglaze 's restoration thread, but it seemed like he didn't actually make the metal bits from what I can tell...
I'd think for some areas (like between seat tube and stays) I would want a couple pieces of sheet metal, rather than just one with loads of filler... also wondering whether aluminium is really the best material for that (and where to source it)?

OK so I will share my plan of how to do this. Start with standard steel or ALU frame. Wrap key sections in fiberglass. Build up aero sections in foam. Wrap again in fiberglass. Sand, filler, sand, paint.

Thanks! I have looked through @monoglaze 's restoration thread, but it seemed like he didn't actually make the metal bits from what I can tell...

Yeah. I thought so. You could probably get them cut and welded on. That process did sound much easier than the sheet metal idea and IMO looks nicer (between TT and DT).

also wondering whether aluminium is really the best material for that (and where to source it)?

Where did you get aluminium from? I have absolutely no idea regarding this.
I'm not in London but where I am there is a hardware shop that does (I think) sheet metal and wood... And fireworks. I'd be incredibly surprised if there wasn't an equivalent in the whole of London. Just search on Google maps hardware stores and then Google them.

That sounds a bit easier to incrementally alter - I hadn't thought of fiberglass... Any idea what type of fiberglass? I have a load of this stuff lying around, as it was left over from some roof work:

It needs a resin to set (which can either be applied by spray or brush), but I could see it working in the way you described (but probably would need several layers because it is quite thin).
This seems like it would definitely be cheaper, lighter and more reliable than trying to use aluminium sheeting (readily available of course @HHC but getting the right thickness and alloy was my concern as I reckon with an alu frame I would have to solder as TIG welding would be too expensive, and brazing/welding has too high a temperature, I think).

Probably marine grade but I'm sure that stuff would work? I mean its non structural anyway

Cool. Post you're progress here when you get round to it.

^utterly mad

^^^ expensive ass saver