Insulation foam fairing for my ebike gas generator hybrid? Good or bad idea...

[bakaneko]

So, I decided to just invest some more into my hybrid versus building a 125cc equivalent emoto. That being said, I like to make the hybrid look less duck tape-ish and create a true cafe racer style to it. Also, need to move some of the electronics from the generator since the pull cord seems to get stuck so much and I will probably need a better battery at some point with good cells for once.

For the fairings, I was thinking of using insulation foam or XPS foam board. I have a gift card for the hardware store. It is a 1/2" 4x8 and I will cut different pieces out to get that cafe racer look and curves. I think this stuff is tough enough to withstand a bike drop and then I will encapsulate the generator engine (with airflow holes) to also reduce noise. I can use my dremel to smooth out the sides and then spray paint parts and put some faux leather to get a better look.

This stuff is waterproof and feels sturdy; I will probably double it up to 1" for the fairings. LOL, is this a good idea?!

 

[Herman Klutz]

Do some research om "poor man's fiberglass".
Start here http://www.tnttt.com/viewforum.php?f=55&sid=2b1ad9807fab195f1a29cd4f4f6bdee1
Next search for "rowerwet".

 

[bakaneko]

I got a 4x8 1/2" sheet of black mendable styrofoam. we will see how this works out. but dont really want to work on something that i wont ride for 3-4 months versus playing video games that will give me satisfaction right now

 

[Old Busted Hotness]

The foam is easy to shape, but it's not tough at all. You need to coat it with fiberglass cloth and resin on both sides, both for strength and to keep moisture out of it. And that's gonna make it heavy.

 

[Herman Klutz]

Here is another idea. http://ratrodbikes.com/forum/index.php?threads/led-sled-sidecar-project.26096/

 

[bakaneko]

the foam is not plush but not as hard as the insulation foam panels. ill put it on first and then see if i need to plaster something on it. ty for suggestion

 

[Chainlube]

Make your basic shape out of the foam and then cover it with tinfoil. Fiberglass over it, several layers, wet out with resin, put down the mat, wet out the mat. Repeat for each layer. Now pop out the foam, then it can be sanded and finished. You can fiberglass in the mounting hardware underneath, any captive nuts fill with cloth and foil first. Then you can sand off any spillage.

 

[nwguy]

Old thread I know, but if you're interested in making a fairing with foam, see John Tetz's projects. Sadly he died in 2020 but left a legacy of foam shelled recumbents.

 

[Chainlube]

Old thread I know, but if you're interested in making a fairing with foam, see John Tetz's projects. Sadly he died in 2020 but left a legacy of foam shelled recumbents.

That's the way I'll be heading with this new (yet to be named) project. I want it to look more like a race bike than a M/B.

 

[darwin]

Too delicate, 1 bump and crack!