Zote Foam Wheel Covers

For construction I basically followed the directions I found here:

http://www.recumbents.com/Mars/pages/proj/tetz/other/wheeldiscs-new.html

Only thing I might change is I don't think the stiffener was really needed with the 1/4" Zote foam I used. On the rear wheel where I was running into clearance problems with the chain I left if off that side. It made the installation look a little bit better as the cover hugs the wheel much better. I bought the Zote from Mark Mueller at Windwrap Fairings  and the contact cement and industrial strength Velcro from Wal-Mart. I used a 1/4" by 20" X 40" sheet of Zote per wheel. I bought an extra sheet just in case and I was thinking about re-building the outside front discs. This time I would not use the extra stiffener and not cut out the hole in the middle of the disc as I think it would make a cleaner looking cover. Total cost of the project was around $60.00 not including the labor. It took approximately 5-6 hours time.

4/30/06 Update
I took the disks apart today and removed the stiffeners. This made the discs hug the wheels and look a lot nicer. Have noticed no problems doing this.  I have had some questions asked about the Velcro holding, however it has worked great so far with no problems. I really cant say that I have seen an increase is speed, but definitely I can be seen much better. I can tell a difference with a strong side wind as it does blow you around somewhat.  Nothing dangerous, but you can tell it.

The inside disk has some spacer blocks added to make up the difference in the width of the wheel. I had to enlarge the hole on the inner disc to clear the brake caliper. The Velcro sticks very well and it does take some effort to remove the discs, I don't foresee any problems with them accidentally coming off.