This time I made a Cervelo S5 aero multi-mount with a 3D printer.
With nothing attached, it can be used as an aero-shaped cover, and if needed, it's a mount that can hold a dashcam and light.
I've often seen S5 users' mount rivets pop out due to the weight of speedometers, lights, and dashcams, and there also seems to be quite a bit of demand for the integrated aero covers coming out these days, so I combined the two.
Self-studying CFD analysis took quite a while, but the results show about a 35% watt savings under the same settings (40km/h speed, headwind). That said, at 40km/h the numerical difference isn't hugely significant, and I think you'd need downhill-level speeds to get a more dramatic aero effect. Since riding conditions don't always mean a pure headwind, I plan to analyze crosswind conditions a bit more.
Also, since it carries a fair amount of extra weight, I modified the design from the old structure that clamps the round handlebar from top and bottom, and additionally inserted a CNC-machined 3T carbon plate in the middle to reinforce strength. As a result, it held up sturdily during rides.
And since I didn't like the step created when you raise the stem, I made and attached a design-complement piece together with it.
Now that my baby is born, riding and tinkering with the 3D printer have both gotten harder, but I'll come back and share again whenever I make something.
