Fork part 4: done

Finished the fork this week. Realized I spent about 20 hours working on this, which is a lot, but it was worth it. I think it looks great, there are some small imperfections, but you have to be within 6 inches to see them.

Blade dimensions are: 14.2mm wide and 80mm deep.

I had been tossing this idea around in my head for a bit, but then it was confirmed as a possibility when I read this post from Mr. John Cobb.

I had been tracking fork blade width and depths to try and see what already exists and came up with this table:

I couldnt get the width of my Cervelo Chord fork down into the range of the Lotus or Time Bandit (~10mm), so I made it a little deeper. But stayed within the depth Cobb suggested. If I started with a Jetstream could get it to be 8:1 ratio!!

Anyway, enough talk, here she is:

No more dust

I've been using cheap disposable masks to protect myself from dust lately while sanding the bondo on the fork.

But I just bought this for $8 shipped. Hopefully, less crud gets into my lungs.

Fork part 3

The base wood has been glued on, I applied the Bondo Glass filler and have gotten the outside of the fork blades to be very smooth. Its looking really good.

Now I just need to apply more body filler to the insides of the fork blades.

 

 

 

Fork Add on pt2

This is what I'm thinking for the fork addition:

• sand down fork (to roughen and possibly thin fork blades down past the Cervelo decals)
• glue on base wood strip (wood strip wont be as deep as the final depth of the fork)
• fill in bondo glass to create airfoil
• sand bondo and smooth
• fill in any surface imperfections with bondo body filler
• primer
• final coat of satin black
• satin clear coat

Fork Add on

Here's a before and after of what I'm thinking of doing to my fork. Adding 34mm (1.33 inches) to the back of my stock Cervelo fork to increase the depth.

Edit: the fork started out as 544 grams.