Low Cost Aerobar Upgrade Kit V1.5

The following is a low cost adjustable kit designed to convert cheap 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 at in local Time Trials, Triathlons, Track Pursuit, and Kilo.

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 an interlocking system to prevent rotation.  See bill of materials for all parts.

I have both the adjustable and monolithic versions for download in STL format.  The monolithic ones are for my long ass arms, you can combine the pieces to make your own custom length monolithic versions.

Not included are my weird grips that I made from a laser scan of an impression of my hands.

MAKE SURE TO MIRROR  IN YOUR SLICER FOR THE LEFT SIDE.

1. Print the kit

2. Put in the inserts

3. Slide the gap fillers onto your extensions

4. Slide on the forearm rest clamp

5. install forearm rest.

6. Adjust and install all the set screws.

   Part	Source	Count per container	Cost	Quantity per Kit	Cost Per Kit
   Stainless Steel Flat-Tip Set Screw, 18-8, M6 x 1 mm Thread, 10 mm Long	McMaster-Carr	25	$5.29	12	$2.54
   18-8 Stainless Steel Low-Profile Socket Head Screws with Hex Drive, M6 x 1 mm Thread, 10 mm Long	McMaster-Carr	25	$10.47	6	$2.51
   ASA Filament	Creality	1000	$22.99	442.76	$10.18
   ASA Filament	Creality	1000	$22.99	45.36	$1.04
   M6 Threaded Inserts Short - 25 Pieces RX-M6x6.8 Brass Heat Set	Amazon	25	$9.99	20	$7.99
   Recycled TT Extensions	Ebay	2	$25.00	2	$25.00
   EVA Foam 5mm thick	Amazon	5	$11.99	1	$2.40
   VELCRO Brand Heavy Duty Fasteners | 4x2 Inch Strips with Adhesive 8 Sets	Amazon	8	$7.98	3	$2.99