So I have been wanting a disc wheel for time trialing for some time now. The problem is that I cannot plunk down $795 for a Renn 5ive-5ive-5ive wheel nor did I have time to order the the Aero Disc Covers for $90 at WheelBuilder.com.

So I fired up Google and found this ARTICLE and this YOUTUBE VIDEO. This got me fired up thinking I could actually do this.

So I called around and finally got in touch with Josh at Vital Signs and Graphics in Webster, NY. Josh was nice enough to sell me a 4′ x 8′ sheet of corrugated plastic for this experiment.

This is what I ended up with:

Now I still have to attach it to the wheel. I could use zip ties, but that would leave me with a nub sticking out for each zip tie I used. It probably won’t hurt the aerodynamics too much, but I’d like it to look as clean as possible.

If I could find something like this:

I’ve searched online at Lowes and Home Depot and haven’t seen anything. So hopefully I will get it all mounted tonight and can tested it tomorrow before the Jon Dechau TT on Saturday.

UPDATE: (06/19/2010)

I was able to get the disc mounted, but the problem I discovered is 4mm corrugated plastic really is too thick to make a rear wheel cover. It wouldn’t allow my rear hub to spin freely. So I removed everything and will just run my 1996 HED Alps wheelset. I’ll have to source some thinner corrugated plastic (2mm?).