The first day of competition! The Grind is fully assembled and ready for the sprints!
A little bit of taunting never hurt anybody.
Shaping the windshield gave us some difficulty, but we made it work.
The bike was finally almost fully assembled, we just needed a few finishing touches.
Stress testing on the roll bar…and it holds up! We tested with over 100 pounds of stress.
It started with a little wood frame.
High-density foam was added to the frame and it was ready to be shaped.
Hand-shaping the foam was an exhausting, but rewarding experience.
Now it’s starting to look like a fairing!
Chemicals, hardeners and bondo were applied to the plug in preparation for the fiberglass mold process.
Fiberglass weave was draped over the mold and covered in resin to hold it in place. Here, Max Chinowsky rolls the air bubbles out of the fiberglass.
Team President Derek Fromm applies PVA mold release in preparation for the the second fiberglass mold layup.
We created the mold in three parts. Here you can see the first one already made on the left, while the second half is prepped for the layup.
All hands on deck for the carbon fiber layups
The whole team secures the vacuum bag around the mold to create an airtight, pressurized environment for the carbon fiber to set.
Kyra Schmidt and Ryan Meinhardt listen for air leaks in the vacuum bag.
The vacuum’s suction pulls the bottom mold inward. A scrap piece of foam keeps it from warping.
Engineering drawings for our reverse-gearing mechanism
We machined the the gear system from aluminum stock in the Aero Hangar
The final design. A servomotor engages or disengages the sleeve with the non-freewheeling side of the drivetrain, allowing the bike to pedal in reverse.
Sam Porter, who designed the reverse gear mechanism, runs tests on the prototype bike.
The reverse gear is finally ready to install on The Grind.