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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Tue Jan 14, 2014 11:36 am 
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Hi guys,

I have two handles with the following measures ready for you to test (the ones shown in my tutorial thread):

3cm wide alloy
5mm alloy thickness
8cm high (Including foam grip)
13cm wide (Including foam grip)

Send me a PM with your adresses I shall have it shipped to and youre good to go for a testrun as soon as they arrive.

After some testing, please give me feedback on possible changes. (I think we got the material and measures almost exactly right)

I am sure this is already 90% ideal.
I will not glue the foam (to leave you options)

I would recommend the following:

1. Test with foam without glue
2. Test with tapes (remove foam, tape it)
3. Test with foam glued (I guess that will be the solution)


Have fun testing and please write me detailed feedback!

I will do one more for me (but 1cm lower as I have a 8cm instep, 1cm lower than Tobi)

After your detailled feedback I will then produce another handle for each one of you so you can test the optimised version - so the more specific you know what you want, the better!


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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Fri Jan 17, 2014 10:07 am 
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Posts: 206
Alright,

the two handles are on their way by express box. Happy testing :-)

Meanwhile i figured out a few more things (see pic below - got a whole bunch of fresh alloy, EPCM Foam, Tapes, Washers and screws delivered for custom building this weekend :-)))

I will try to make a Handle with 8mm thick alloy (no idea if we can bend it - if not I will need to try 6mm (couldnt get 6mm alloy yet, out of stock).

Because my foot is obviously smaller than Tobis (1cm lower instep) I will make it 7 cm high instead of 7,5 and 12,5 cm wide instead of 13 wide.

I will round the edges massivly for more comfort, then put the BBB Bike Grip Foam on it and glue it completely all around with an injection needle and superglue. If that doesnt work well (But I guess it will work 100%) I will use the two tapes (tennis 1st layer, Marine Soft grip 2nd layer)

Then I will use longer 16mm M6 screws and industry washers (inserts are 7mm deep as far as i remember)

Will report soon.

I will also produce custom grabrails for the Flyradical 3 128 and glue them on with JD weld epoxy.


Attachments:
IMAG0296.jpg
IMAG0296.jpg [ 806.53 KIB | Viewed 668 times ]
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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Fri Jan 17, 2014 2:46 pm 
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Joined: Mon Sep 24, 2001 1:00 am
Posts: 29543
Location: World (KF Admin)
Wishing you a productive weekend ;-)


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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Fri Jan 17, 2014 8:20 pm 
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Sure you do :-) as one of the grabrails goes to you as a late Christmas present ;-)


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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Fri Jan 17, 2014 10:55 pm 
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Joined: Mon Sep 24, 2001 1:00 am
Posts: 29543
Location: World (KF Admin)
don't go party, stay at home! :thumb:


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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Sun Feb 02, 2014 5:12 pm 
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OK,

heres a short update:

We managed to get the Leo customs T-handles to a new level, very close to the final product now:

- 8mm alloy for highest durability while stil leigh weight
- welded molds to customfit the alloy 100% accurate
- heatforming at 250-450 degree
- rounded edges for a comfortable grip
- EPDM foam cover ultratight fit, applied with icefilm / waterfilm at 0 degree
- injected glue 360 degree (2 versions: superglue and epoxy by JD Weld)
- optimised measures (1cm less high, 1cm less wide - resulting in 7 height and 13 cm width) for better fit when doing Foothandle tricks

Attached find some pics.

Toby, I send you another handle (including screws and washers), please give me feedback on durability, new measures and how it feels with the new glue fixed foam).


Thanks


Attachments:
IMAG0345.jpg
IMAG0345.jpg [ 921.74 KIB | Viewed 371 times ]
IMAG0342.jpg
IMAG0342.jpg [ 943.47 KIB | Viewed 371 times ]
IMAG0340.jpg
IMAG0340.jpg [ 855.19 KIB | Viewed 371 times ]
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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Mon Feb 03, 2014 1:54 pm 
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Good work :thumb:


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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Mon Feb 03, 2014 2:35 pm 
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looks awesome!

Just saw mine bend from all the t-handle kickflips...so 8mm is better for sure!


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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Mon Feb 03, 2014 8:47 pm 
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Joined: Sat Aug 29, 2009 11:25 pm
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Macisback wrote:
OK,

heres a short update:

We managed to get the Leo customs T-handles to a new level, very close to the final product now:

- 8mm alloy for highest durability while stil leigh weight
- welded molds to customfit the alloy 100% accurate
- heatforming at 250-450 degree
- rounded edges for a comfortable grip
- EPDM foam cover ultratight fit, applied with icefilm / waterfilm at 0 degree
- injected glue 360 degree (2 versions: superglue and epoxy by JD Weld)
- optimised measures (1cm less high, 1cm less wide - resulting in 7 height and 13 cm width) for better fit when doing Foothandle tricks

Attached find some pics.

Toby, I send you another handle (including screws and washers), please give me feedback on durability, new measures and how it feels with the new glue fixed foam).


Thanks


Is that stainless screws and washers to install that aluminium handle?

In a salt water environment you will get galvanic corrosion between stainless and aluminium.

My suggesting is to use plastic washers between the screws and the aluminium.


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 Post subject: Re: Custom Airstyle Handlebar Developement - CNC production
PostPosted: Tue Feb 04, 2014 4:10 pm 
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Joined: Fri Sep 06, 2013 2:20 am
Posts: 206
@ Toby: I hope with bending you mean the very old one with 3mm you had, not the 5mm I sent you? Any testresults for the 5mm T-handle yet?

@s1buell: Did your T-handle I sent you arrive already? Any testresults yet?

@plummet: the washers are stainless with a zinc layer on top, so I guess no galvanic corrosion


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