I've got a bit free time over the summer and since I have access to a machine shop I figured I'd make something quick and fun for my bike. Hope this is the right forum.
My steerer tube is still uncut (commitment is a big and scary word), so I have a 20mm cone spacer and two 5mm spacers sitting on top of my stem. They're not load bearing and spacers are pretty easy to make, so I figured I'd make my own single-piece 30mm spacer out of some spare 6061 aluminum I have. Here are a few pics of the process.
Made a design in Solidworks based on some headset spacers I saw on Fairwheel.
Doing some basic FEA. The spacer should be able to sustain a normal load of 50lbf. I was concerned that it might snap while being held in the vice on the mill. I ended up making the pillars wider during fabrication anyway.
Freshly parted off! Not shown: deburring, Scotch-Brite, polishing wheel.
First pass on the first cutoff - I was pretty nervous! Can't clamp it too hard that it crushes the spacer but I also didn't want the spacer flying off as soon as the end mill came into contact. Solution: sharp carbide end mill, lots of oil, and a slow power feed. Advanced a depth of 1/32" per pass. If anyone's interested I can talk about how I got the cutouts to be perpendicular to each other.
Fresh off the mill. Gotta do some finishing work.
Cleaned up and did some light filing.
Old setup. Note cone spacer.
That's simply too many grams.
That's more like it.
If nothing else, it looks lightweight
I'd like to make it black somehow, but I haven't really thought about it too much. Maybe I'll just run it naked for a while so people can ask me about it
Fabrication: ~3 hrs
A bit about the bike: http://www.pedalroom.com/bike/2013-scott-foil-17104
It's kind of a fatty at 7.71kg.
Hope you guys enjoyed the pics!