DIY aerobar

I’ve tried using conventional aerobars and just couldn’t find the comfort and performance I was looking for. My elbows were always too close together to be able to breathe properly and have reasonable power outputs. Starting with a broken carbon fiber ski pole and some foam sheet, a series of prototypes were developed and tested over the past year. The version outlined in this post is the one that I find most comfortable (multiple hand and arm positions), versatile, and quickly removeable without any tools. An added benefit of the DIY aerobar and secure mounting system is that the upper body and core can be recruited for more powerful pedal strokes. Based on a few hundred kilometers of observations I’m about 1.5 km/hour faster with DIY aerobar than the conventional system. I think this is because of the more open chest and upper to lower body power transfer. The system pictured weights about 200 grams installed. This DIY approach is also significantly lighter than the conventional carbon fiber aerobars used in this post.

The cork yoga ball is drilled and glued onto the inner length of tube. The ball and tube can be quickly removed from the outer tube for other uses.
Completed installation with elastic cord for securing gloves and other items. Less than 2 minutes to install or remove
2 segments of Thermarest Z- Lite Sol, and a piece of corroplast for internal stiffening. The foam is also used around camp and under the hips as part of my sleeping system.
The placement of the OneWrap on the folded foam helps determine elbow placement.
Side view with the Fenix light mounted (with OneWrap) to the front of the Jones bar.
Completed aerobar lashing and two 22″ sections of OneWrap hanging to secure the elbow pad.
Front figure 8 lashing completed.
Completed rear figure 8 lashing
Positioning bar into front and rear Velcro patches.
Riser segment made from PEX and wrapped in industrial Velcro. This piece is to fine-tune aerobar angle and comfort.
Industrial hook Velcro pad on stem creates a saddle for the end of the tube. More industrial Loop Velcro is applied to the handlebars.
Recruiting upper body for pedaling
Strapping one side of the mat to the Jones bar.
Figure 8 lashing with OneWrap 22″ long.
The blemish on the yoga ball is from drilling too far, and then patching with glue and cork fines.

Development notes:

The stiffening panel between the foam is critical to overall functionality. I started off using cutting sheets, which would be shredded after a hundred kilometers of riding. The addition of the removable cork ball added comfortable hand positions, likewise for the triple layer of cork tape. Finding the correct length took some trail and error. Start longer…