Fully faired recumbent

31-03-08
I should receive the fairing in less than a week and I am a bit nervous to see if it looks like what I have got in mind. If required, I will make minor adjustments on the basic shape. I wonder how much bigger it is compare to Francesco's speed bike.


Final assembly. It looks like a big tuna fish on its side.


After all the parts are machined, assembly can start.


After removing the dust, the fairing is clearly vissible. As the foam sheet was too small to make the fairing in one piece, the tail is machined in the middle.



The fairing starts to appear under the dust.



The machine has started its job. There is no way back!



31-03-08
The fairing is already in the foam, incredible if you think about it!
The 3 sheets of PU foam will be machined separately and then bonded together.



14-02-08

I have started the mock-up of the frame.
I redesigned the chain path because the derailleur is either too wide between my knees or too close to my heel. The cassette will be placed below the wheel hub. I still need to check the interaction with the steering.
Anybody tried that before? What was the result?


I shaped a block of foam to get a better view of the work to come. I have decided to subcontract the 3D modelling to a friend of mine so it can be used by the CNC machine. I will still do some hand work on the foam but it should be quicker and symetric!
I have also decided to reduce the canopy size so save a bit of money during the trial and error process.

17/01/08
After talking to my friend Francesco Russo, I realised that my preliminary fairing (based on the shape of EIVIE I, supplied by Damjan) was too tall and too narrow in way of the crank.
Francesco kindly supplied a couple of X-sections of his bike as a guide line. There is a mistery right now because he is taller than me but fits in a smaller fairing. I am currently using 170mm crank and I can reduce it but there is a danger of designing a fairing too small. I left 10mm gap between my shoes and the fairing.
I made a 3rd attempt to design the fairing in 3D and I can't get the shape I want. It is getting better but I am now tempted to shape it by hand instead of CNC machining the foam.
10/01/08
I changed my mind about the frame because I think it will be quicker to do everything myself in carbon. The carbon frame will be fitted to conical female boxes (similar to a windsurf board fin).
The crank will be on the left handside so a skirt can be used to seal the wheel exit on both sides.
Main dimensions:
Length: 2911mm
Wheel base: 1437mm
Max height : 843mm
Max width: 445mm
I still need to make a moke-up of the position with MDF to check the fairing voulume required. I want to make the fairing the right size.

----------------------------------------------------------------------------------
I have been working for sometime now on a speed machine.
This is not an easy task but the joy to ride at 70Km/h with my own (little) leg power is pushing me.
A friend of mine will CNC machine the mould and I should start the fairing construction in February.
I am still looking for some help to build the metal frame (similar to a VARNA Diablo).
I will make an attempt in May and July 2008 to set new French records.
Here is the first pictures of the fairing.

BB Lowracer

26-01-08
The frame is finally finished.
The varnish messed up the white paint a little bit but it is now too late to do anything. The derailleur lug has been added and I am now preparing the chain stoppers.
Final weight is 1650g as you see it.


The paint job is underway.

I have started the paint job. I used a polyester clear coat to get a nice finish then I used plastic electric tape as a masking tape for the spray can.
A friend will spray a gloss varnish soon.
The next stage will be bond the idler thread insert.
Stay tuned!


This is the new lowracer frame for Barbara Buatois, the current double world champion. This frame will be dedicated to road racing while her Cobra 'ultra'lowracer will only be used on tracks because it can't be used on bumpy roads.
The frame is build over a polystyrene foam core and covered with a couple of carbon socks (+/-45deg and 0deg). The bottom braket is coming from an old aluminium Mountain bike frame. The front derailleur post is kept for ease of construction and because there is less risk of being damaged by the clamp.
The current weight before painting is 1402g.
The final weight should be about 1500g.

More pictures soon.

Class 40' Construction

A good friend of mine is currently building his own Class 40'. (new European racing Offshore sailing yacht). Elie Canivenc (ECAN) designed and built a mini transat boat (6.5m) two years ago and decided to build a larger and more exiting sailing boat.
As a structural engineer, I give him some help and advises on the structural side. He has done a great job so far and the boat should be ready to set sails next summer.
The hull is made with multiple pre made flat panels infused a large table. This method is used so that a single man can build every panels alone, trim and assemble them. The infusion process garantees minimum weight and time saving. Chined boat have been very competitive in this class before they reach high speeds.
Enjoy!
PS: the green tuff is only peel ply.

Paris Brest Paris 2007

A the end of August, I completed my first Paris Brest Paris (1250Km non stop) in 80H 3min.
The weather was very bad and I got a lot of rain during the first 480Km. Roads are not flat but if you choose the right gear then it is not a big deal. (11000 climb).
My High racer recumbent (10.2Kg naked) was surprisingly fast up-hill compared to other recumbents.
I used liquid food 640 from OVERSTIM and MALTO+HIDRIXIR in a separate bottle. These products work very well with my body and I now think that they make a huge different after 600Km. Your legs never feel empty and your body gets the energy on time every 10min.
The recumbent was a real advantage in the last 400Km because we could ride faster than normal bikes and we had no saddle pain. I overtook more than 500 guys who struggle to find the right position on their bike.

I did this PBP to explore my limits and I found that my kees need attention ( more training, more cold protection or new position).
I will certainly do PBP again but with a target of 70H next time.
Next long race: Bordeaux-Paris 2008 -650Km - target 25H

KIDAM 2007

Race KIDAM in Paris on the Jacques Anquetil outdoor track (La Cipale)
Course du KIDAM à Paris sur le vélodrome Jacques Anquetil ( La Cipale).
Kilometre standing still: 1min18s20'. Result slower by 4s than 2006
Kilomètre départ arrêté: 1min18s20'. Résultat en retrait de 4s par rapport à 2006. Manque d'échauffement?
200m flighing start: 13s20'. Result slower by 1s than 2006. Can't ride over 60k.
200m lancé: 13s20'. Résultat en retrait de 1s. Sensation de saturer à 60Km/h.
1 Hour race: 43.7Km/h average despit losing 2 laps due to stiff legs. (again!).Nevertheless, I finished the last few laps at 44-46Km/h average.
I finished 3rd overall.
Course de l'heure: 43.7Km/h de moyenne malgré un arrêt de 2 tours à cause de campes (encore!). Je termine tout de même les derniers tours à 44-46Km/h.
Je termine 3e au général.
Pas de courses le dimanche à cause de la pluie.
Denis is leading the pack.
Denis mène la meute.

Speculos testing in the Women rest room. Racing atmosphere
Essai de speculos dans le vestiaire des femmes. Ambiance course.

Championnat de France FFC/AFB sur Route

Le 13 Mai 2007 se déroulait le Championnat de France FFC/AFB sur route à Lève au Nord de Chartres.
La pluie s'est invitée au départ de la course de 90Km et la route détrampée a apporté son lot de petites frayeurs. Le rythme de course a été soutenu dès le départ et Denis Lotte termine en 2H15'38 soit 39.81Km/h de moyenne alors qu'il y avait pas mal de vent. Je termine 3e avec un peu de chance car Gérard Lascombes (Coyote) s'est perdu dans un village.





Départ des 15 concurrents.

Première cote avec Barbara Buatois à mes cotés (photo: Jean-Lou Desbarbieux)

Podium officiel FFC avec son représentant Roger Bordeaux à droite.

1er: Denis Lotte 2H15'38 (39.81Km/h de moyenne sur 90Km)

2ème: Marc Lesourd 2H23'26 (37.65)

3ème Malric Leborgne 2H33'41 (35.14)

Carbon Low racer

9-03-08
First test of the bike today.
After bonding the seat,I realised that the bottom bracket was 20mm too far so I had to trim the frame!
The first test is always scarry because something can break but nothing did.
The forward part of the frame is not stiff enough so I need to reinfrce it. The global stiffness seems to be acceptable.
I can fit a front break at the moment so I need to find a solution soon at it is not acceptable to ride on a road with a single rear break.
The fork has not the correct angle but it is too late to change.
The final weight of the complete bike is 7.8Kg. My target was less than 7Kg so need to up-grate a few things like the handle bar, the foam pad and the rear wheel (1.8Kg!).


8-3-08
Carbon Fork.
I already built a carbon fork two years ago for my Baron X-low because the chain was touching the fork. So I built an asymetric fork similar to the VK. I start from a foam former. I laminated a couple of layers of carbon (UD and +/-45) to form an arch. Then I used a PVC pipe as a former for the steering tube. I laminated more carbon and vacuumed bag the whole lot. As expected the sttering tube was far from perfect so some carbon had to be ground off. The final weight was about 290g and the stiffness was just acceptable sideways.


From that first experience, UI decided to use a female mould for the steering tube. I wanted to use a badder to build the tube but at the last minute I decided to use a piece of round foam that would be soft enough to squizz when the female mould would be closed.
Arch laminate over full width:
1 x CAUD300-620mm long ( carbon unidirectional)
1 x CADB400-620mm long (carbon double bias +/-45 stitch fabric)
2 x CAUD300-620mm long
4 x CAUD300-270/230/200/100mm long
2 x CACL300-220/200mm long (carbon cloth 0/90-weaved fabric)
1 x CADB300-620mm long

Steering tube:
1 x CADB400-190mm long (carbon sock +/-45)
2 x CAUD300-33mm wide-500mm long
2 x CAUD300-33mm wide-275/200mm long
8 x CAUD300-25mm wide-225mm long
1 x CADB400-225mm long (carbon sock +/-45)

On the picure below, you can see the arch built on a boam former, a small piece of PVC foam (AIREX C70.75) bonded a the top to take the local shear load and align the female mould, the'soft' foam round piece and the precut carbon. The carbon is laminated on a table and the excess of resin is removed with a squeegy.


Each layer is then applied on the fork and they are 'hand pressed' to remove any bubble


This is a carbon sock (+/-45). This a wonderful product as it fits almost every diameter and you don't have to worry or struggle with the +/-45 distorting too much.
It is also possible to buy unidirectional sock.


The female mould then clamps the steering tube. I advise that use use a sacrificial layer as the last layer might be trapped at the join. Many bolts and a stiff mould are required to garanty a good clamping pressure. I then fitted everything in a high elongation vacuum bag from AEROVAC (400% elongation)because I had a sample. I left the foam former in the arch because it had a centre line and it has be used to align the steering tube. I cooked every thing at 40degC during 2H30. This garanties that the resin is totally fluid and will impregnate the carbon totally.
Final weight of the fork is 260g but more trimming can be done.


20-2-08

After 40min of foam shaping, I was ready to laminate the underside with a layer of carbon/Kevlar. (that is the only material I had in my garage at that time.) The upper and lower skins overlap over 15mm alround the seat. I also added 3 transverse carbon UD reinforcement 30mm wide in way of the expected support points.
Final weight is 470g.

18-02-08

I used a sheet of polystyrene 100mm thick to make my seat. Two MDF profiles were used with a hot wire to get the correct curve. The foam is wide enough to make 2 seats. For my next seat, I will use a heavier density foam because it will be easier to sand. The inside surface has been then covered by a layer of carbon cloth 300g/m2 (weaved 0/90)

14-02-08 Back on track.

The bottom bracket in bonded in the frame with filled epoxy. I wrapped a couple of carbon fibres arround the outside to build up the local thickness. I need to make a nice fillet and vacuum bag a couple of tapes (+/-45deg).

The carbon bottom bracket is built on a tube wrapped in a teflon adhesive film. The thread is an Italian/english adaptator thread. I applied 2 layers of carbon (carbon cloth 300g + carbon UD at 90deg and a couple of fibres diretely on the thread) and demoulding the bottom brackets comes to just 15g instead of 50g for its aluminium counterpart.
04 May 2007: The frame has been sanded and is ready to received a layer of vanish.

Wheels are fitted but the crank is still missing.

Le cadre a été poncé et est prêt à recevoir une couche de vernis.

Les roues sont montées mais le pédalier manque toujours.


The front wheel is not as close to the frame as expected due to head set bearing (1'' is higher than integrated 1''1/8)
The shimano back wheel is a bit heavy but it should be very streamlined. Testing will tell.

La roue avant n'est pas aussi proche du cadre qu'espéré à cause de la direction head set (1'' est plus haut que 1''1/8 intégré)
La roue arrière shimano est un peu lourde mais devrait être très profilée. Les essais le diront.


The peel ply layer and the mesh used during the vacuum process are partially removed.

Le tissus d'arrachage et le fillet utilisé lors de la construction sous vide sont partiellement retirés.





15 April 2007:
I have just started a new carbon Low racer frame.
Je viens juste de commencer un nouveau cadre de Low racer en carbone
.

The crank is placed as low as possible to maintain a good blood pressure in my legs. I also feel that it is important to cool the front the legs.
Le pédalier est placé aussi bas que possible pour maintenir une bonne pression sanguine. Il me semble aussi important de refroidir le devant des jambes.


The chain is as straight as possible. The bike will be fitted with Corima wheels.

The core is made of extruded polystyrene (Yellow) 50mm thick.
The entire frame is covered with a layer of carbon double bias(+/-45) 300g/m2 + a layer of carbon cloth (0/90) 300g/m2. I have added a couple of local reinforcement (unidirectional) to stiffen the frame ( a drawing will be added later)
Foam core: 238g
Aft fork covered: 350g
1/2 side covered: 700g
Expected final weight: 1200g

La chaine est aussi droite que possible. Le vélo sera équipé de roues Corima.
Le noyau est constitué de polystyrère extrudé (Jaune) de 50mm d'épaisseur.
Le cadre est entièrement recouvert d'une couche de bi-biais (+/-45deg) 300g/m2 et d'une couche de carbone sergé (0/90) 300g/m2. J'ai ajouté quelques renforts locaux ( unidirectionel) pour rigidifier le cadre. ( un dessin sera ajouté plus tard)
Noyau mousse: 238g
Fourche arrière couverte: 350g
1/2 coté couvert: 700g
Masse finale probable: 1200g.

High Racer

Picture by: Jean-Luc Viala
28 April 2007
First racer of the season on the Toulouse motorbike track. I managed 39.5Km in 1 hour but the High racer is clearly slower than a Low racer. Drafting is also not as efficient as it could be.

Première course de la saison sur le circuit moto de Toulouse. J'ai fait 39.5Km sur l'heure mais le High racer est clairement moins rapide que le Low racer.
Faire l'aspi n'est pas aussi efficace que ça pourrait l'être.


I made a couple of improvements: Second idler, new speedo and cadence system (Sigma 1606 DTS), new wheels (cheap but old and damaged), new Look Keo pedals.
Even if the wheels are not yet perfect (rear rim is broken), I mesuared a top speed improvement similar to my Optima Baron.
The weight is now 10.2Kg complete.

J'ai fait quelques améliorations: Deuxième poulie de renvoie, nouveau compteur avec cadence (Sigma 1706 DTS), nouvelles roues ( pas chère mais ancienne et endommagée), pédales Look Kéo.
Même si les roues ne sont pas parfaites (jante arrière cassée), j'ai mesuré une amélioration de la vitesse maxi, très proche de mon Baron Optima.
Le poids est maintenant de 10.2Kg complet.

Rear view of the bike showing the carbon braket. The tilting tiller is great because the seat is somewhat too high for me. ( I will blame the designer....)

Vue arrière du vélo montrant le gousset arrière de siège. Le guidon relevable est génial car le siège est un poil trop haut pour moi. ( c'est la faute du dessinateur....)

At last, my High Racer got a layer of paint and a couple of stickers.

The bike is fitted with a set of Rigida aluminium wheels. They give surprisingly good results and they are marvelous for training.
the final weight is 10.7 Kg but should improve with a couple of up-grades. (Corima wheels, carbon handle bar, carbon crank, new pedals)

Mon High Racer a enfin reçu une couche de peinture et quelques autocollants.
Le vélo est équipé d'une paire de roues Rigida en aluminium. Elles donnent un résultat surprennant et sont parfaites pour l'entrainement.
Le poids final est de 10.7Kg mais devrait s'améliorer avec de nouvelles pièces. (Roue Corima, Guidon carbone, pédalier carbone, nouvelles pédales.

Car parts

I finaly found what I need to start my car: 18' Alloy lightweight wheels, 320 Brembo brake disc and calliper, complete front suspension, anti roll bars etc... and it is all coming from a Renault Mégane RS.
This is the donnor car, a 2006 car.
After removing the rear wheels, we found that the rear hubs could not be adapted to anything else so the original R25 hub will be kept for the time being.


Right hand front suspension, took about 1h to remove per side.


All the parts:
18' x 8'' Alloy wheel (complete): 22Kg (light weight they said in the advertising!) ask your wife to change it!
Ventilated disc: 7.8Kg
Complete suspension + hub + Brembo/renault calliper : 26Kg