Sunday, November 16, 2008

Progress on the fairing

Mike and I made substantial progress on the new fairing design. More Pictures
This fairing is being built for Mike's Catrike Speed. The Catrike poses a particular challenge for coroplast fairings because of its reclined seat position. Its usually hard to see over a fairing that doesn't hit your knees.

To solve this dilemma, we put a sight channel down the middle that lowers the fairing by 3.5" between your knees. The nails in the picture are just temporarily holding the coroplast to the aluminum frame. Besides dealing with the sight line issue, our other goal was to build this front fairing out of a single 4x8 recycled political sign.

The final challenge was to see if we could successfully copy Ethan Davis's fairing mount. Ethan developed a very clever design that has a jaw that clamps down on a bracket attached to the fairing frame. This makes a secure mount which with a push from your toe releases the fairing for transport or in case you just want to ride unfaired for a while.

Saturday, November 1, 2008

Working on a front fairing out of one sheet of coroplast

I spent the day working with Mike on a front fairing for his Catrike speed. The first try based on a design he had seen online didn't work as well as hoped. It was so high it was impossible to see the road in front of you for about 30 feet. We shifted gears and started with a 8' by 1.5' piece of coroplast left over from my fairing. Its bent around an piece of aluminum that we shaped into half an ellipse to make the leading edge of a vertical airfoil. It's based on Ethan Davis's fairing. What we're doing differently is making two bumps with a channel down the middle. The bumps provide knee and toe clearance and the channel provides forward visibility. We're making the prototype with scraps and recycled signs but it looks like this design could be made with a single 4x8 sheet of coroplast with limited cutting. We hope to finish it up tomorrow and get both pictures and plans up soon.