Aero bar mounts

This was going to have a little welding in it, but I changed my mind. I was going to make it out of half inch and build up the top part with weld, but in the end I just whittled it out of 3/4 stock, instead. These are mounts to attach some areo bars to a pair of bicycles.

Started with 3/4" x 2" 6061 T-6 extruded bar.

Attachment 7302

Carve out one side.

Attachment 7303

Flip it and do the other side. Bore the holes and profile the part out.

Attachment 7304Attachment 7305

Flip again and drill, tap, clearance, and counterbore a couple of holes. Profile the ends round.

Attachment 7306

Flip and scoop out the top. Drill and tap a hole.

Attachment 7307

Here they are mounted to the bars.

Attachment 7308Attachment 7309

Test fitted on some handlebar tubing.

Attachment 7310Attachment 7311

I'll probably give them a nice glass bead blasted finish to smooth out the machining marks. Although first I have to clear some junk away from the bead blast cabinet, and I think fix some air fittings on it. Shop maintenance never ends.

Nice pieces! Should look even sharper with the blasting done. Thanks for the pics.

or put in a tumbler and polish

Nice work... I like projects with machining.

Nicely done- are you the cyclist? My list of future toys includes "lathe" and "mill" but projects like this move "mill" closer to the top of the list. Do you mind describing your setup?

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Originally Posted by DaveO

Nicely done- are you the cyclist? My list of future toys includes "lathe" and "mill" but projects like this move "mill" closer to the top of the list. Do you mind describing your setup?

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They are for my fiancé and I. A lathe is usually the first machine tool, but these days the line between mill and lathe gets blurry. These parts could have been made on either, but I used a mill. Specifically an old Alliant 42VC 2HP varispeed with an Anilam CNC control circa mid 1980's. Due to space issues I had to get rid of my big lathe, so now I have an import 9x20 that does the job. Space is one of the big reasons I'm looking to replace my TIG machine with an Everlast.

Very nice and clean looking. Did you calculate the weight?

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Originally Posted by NRM

Very nice and clean looking. Did you calculate the weight?

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Nope, I just used a 2D program to draw them out, so no volume calculations. I did try to keep them pretty light, but nothing extreme. They came out to just over 40 grams each, and with stainless hardware just over 60 grams. Actually, until you asked, I didn't even bother to weigh them. ;)

Very nice. Those machined patterns sure look purdy. :) That's some pretty thick bar stock you started out with. My wife has been getting me into road biking as well lately. A fun and healthy activity to do together for sure.