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Modular Racing Bike Mudguard

by mitrasmit, published

Modular Racing Bike Mudguard by mitrasmit Jul 29, 2016
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2988Views 449Downloads Found in Sport & Outdoors

Summary

Racing bikes are one of the best modes of transport. But wet roads can be annoying: you'll get a fountain of water spraying upwards from the tyres. A storebought mudguard/fender is either ugly, heavy, impractical, or just unpersonal, so I wanted another solution.

Meet the Modular Mudguard!
Pick and mix the desired modules (see the STL Name Guide in the pictures) to compose your perfect layout. You'll never have to change clothes after a rainy commute again. If you have other module ideas or if you want any changes, look below for info on customized parts.

If you make one, please please share the results!

Print Settings

Printer Brand:

Ultimaker

Printer:

Ultimaker Original

Rafts:

No

Supports:

No

Resolution:

0,4x0,1mm

Infill:

20%


Notes:

These parts are designed to be printed on their side. To make sure they wouldn't fall over, I printed a raft around the parts, but I think this isn't necessary. Support also is not necessary, unless your printer has trouble bridging. There is one exception: the coutout and bracket in the BracketCutout part need support material. The fit is loose; if you want them to snap together more firmly, consider adding 0,05 to 0,1mm all around (if your slicer can do this). However, you'll need to secure it more permanently to use it on your bicycle anyway.

Post-Printing

Bar attachment

  • I bought stock mudguard bars that connect to the mudguard and frame. It wouldn't be too much issue to make them yourself, but you probably want to make sure it won't rattle when riding the bike.
  • Since my bike doesn't have attachment loops on the frame, I also made my own simple connection brackets. They're customly dimensioned for my bike to the millimeter (11mm and 16mm); if anyone is interested in them, let me know and I'll publish them on Thingiverse as well.

Fixing the parts

There's many ways to do this.

  • The easiest would be a superglue or (if using ABS) acetone.
  • You can also drill small holes through the connection parts and use tiny bolts and nuts. This way, you can change to composition to your liking. However, make sure to use locknuts; everything will vibrate violently, and normal nuts will definitely come loose. Also consider using washers.
  • Rivet together for that industrial look. Again, use washers to avoid destroying the plastic.
  • Weld together by friction welding with filament & multitool (video will follow).

I used friction welding, because it's awesome, fast, and definitely permanent. I made a video that I will share shortly, to give an idea of the very simple process. Black isn't the best colour for friction welding due to the discolouration, but still. Try it!

How I Designed This

Weight

The weight of the Neutral part is 16 grams (PLA, 20% infill, 0,8mm wall thickness).
Both end caps are about 8 grams, and the bracket parts are <20 grams. This means the front mudguard (6 modules) in my composition weighs about 80 grams, and the back mudguard (7 modules) weighs <100 grams. This does not include any nuts, bolts or bars.

Dimensions

This mudguard has been designed for a standard racing bike:

  • 700x23C
  • 23-622 / 17-622

The width of the mudguard is 37mm. At my front fork, there wasn't space to mount the mudguard high enough to not hit the tyre, so that's why I had to create the cutout part.

Each section is exactly 20° of a full 360° circle, or 1/18th. The cap ends are 10°.

The distance from mudguard surface to the center axle of the hole:

  • Bracket: 8,55mm
  • BracketCutout: 13mm

Customized parts

  • As you can see, I removed my hand brakes and switched to a coaster brake. I am not sure if the parts will fit with all brake pad compositions, but if you try it and it fails, let me know and I'll see if I can make a fitting design.
  • The brackets are also custom designed for my own bike, so again, if they don't fit, let me know and I can see if I can easily adapt the model.
  • I will not share the original CAD model, but I am usually really fast with requests, as long as you give me a good description!

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Wow, that's really cool. I had thought about doing something like this but really wasn't sure how to approach it. Looks like you figured it out pretty well. Good instructions, as well. Looking forward to trying this out, thank you!

Thanks! Please be advised that in this setup, the PLA actually wasn't stiff enough to arch the entire distance between the supports on the back mudguard, so it rests lightly on my tyre. Not a big issue, but if I had to do it again, I'd make an extra support beam midway.

Good to know, thanks. It's a tough thing to model and get good results, but yours look really good. When I get a chance to try it, no doubt I'll have feedback.

Hi I love the idea but would it feasible for you to scale the model for a 700x32cc tire?

I could try, I'm not sure if the model will explode if I do. Im guessing with such wide tyres you also have a different diameter. What's the outer diameter of your tyre?

I measured the width of the tires as 30mm and the diameter as 69.85cm from edge of tire to edge of tire. Are there any other dimesions you would need?

I'll give it a try!

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