I wish Dylan would talk about this...
Why not custom 3D print a lightweight ABS fairing behind the fork (70g), then use a fairly affordable carbon mold on that fairing to get it down to 20g? This approach gives you all the control in the world with airflow, especially if you're running deep section rims to control the airflow and pressure zones around and in between the rim. Using the fork fairing to help direct airflow and make the flow more laminar. The airflow would be more controlled, and a fairing coming off the back of the fork would help break the airflow for the leg as well. It might sound crazy, but I've been experimenting with this using a flat out-and-back course and my own 3D printer on a Fox 32 fork, using the rule of 105 for aerodynamics. It seems to be quite effective.
I haven't heard much discussion about this, and maybe it is against the rules, but for NICA races or local events, it seems like a fun way to gain a decent advantage. Another pro tip is to use 30-inch stretch wrap for your inner triangle on non-crosswind days to gain a few watts at almost zero weight. If you want to take it a step further, you can even use 30-inch stretch wrap on the wheel (I know it sounds insane, I should make content on it) to create ultra-lightweight disc wheels for your MTB. You can then directly attach the stretch wrap to Continental Race Kings, getting far closer to the rule of 105 than you otherwise could.
It sounds silly, but it actually works incredibly well. The adhesive is so strong that if you clean your wheel with isopropyl alcohol first, the adhesion is insane. It lasted me 112 miles with no issues on MTB trails, including going off small jumps.
Recap:
- 3D print a fairing behind the fork and behind the seat post (using the rule of 105) to reduce drag, and even use slight dimpling to artificially change the Reynolds number.
- Stretch wrap your inner triangle with one-sided ultra-adhesive stretch wrap (30-inch).
- Stretch wrap your wheel with one-sided ultra-adhesive stretch wrap (30-inch) by taking off your cassette and disk first, then applying it directly to the wheel to make the whole thing one piece, covering the entire diameter.
- Use small silicone dimples on your race day skin suit and aero shoe covers or aero socks to reduce drag, applying them in a similar pattern to the Endura Encapsulator for best results.
*Links:*
- Match this pattern: [Endura Encapsulator Suit](
https://us.endurasport.com/d2z-encapsulator-suit-ssthiviz-blue/12926217.html?affil=thggps&switchcurrency=USD&shippingcountry=US&variation=12926218&gad_source=1&gclid=Cj0KCQjwpNuyBhCuARIsANJqL9O54DhlKA-hgmU1Y4ib2DjuZBT1IMcJDKROYMr_7SI_6txHMP1O5oEaAtN6EALw_wcB&gclsrc=aw.ds)
- Use these stickies: [Glue Dots](
https://www.uline.com/Product/Detail/S-10366/Glue-Dots/Dot-Shot-Pro-High-Tack-Low-Profile-Glue-Dots?pricode=WA9090&gadtype=pla&id=S-10366&gad_source=1&gclid=Cj0KCQjwpNuyBhCuARIsANJqL9M86ZJXxyqrCnzWCngzsyD_7zsmRvArTltAHnmJfPHky03y94DCUdwaAkZDEALw_wcB)
- Use this stretch wrap: [Stretch Wrap](
https://www.uline.com/Product/Detail/S-17973/Stretch-Wrap-Machines/Portable-Stretch-Wrap-Cast-80-gauge-40-x-5000?pricode=WA9377&gadtype=pla&id=S-17973&gad_source=1&gclid=Cj0KCQjwpNuyBhCuARIsANJqL9OcLljqRsQZMWfAlTQi77WnFDtscf8tzen4D1Xwvcu3FNC7w9iYMZwaAgNWEALw_wcB)
I can share the 3D modeled STL files for the fork if you want. They are currently modeled for Fox 32 and 34 forks and RockShox forks. The models perfectly mold around your disk brakes as I 3D scanned the forks into Fusion 360 for CFD testing. I am currently on my 8th model and making huge gains in fork design. I am also working on a forged carbon layup mold to reduce the 3D print weight significantly, so I can manufacture them for some of the kids I coach. I know Josh from Silca hates the whole fairing thing and tall aero socks, but it just feels fun to go faster and know you have an advantage over the competition.