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"Ghettocore" Homemade rim protection

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"Ghettocore" Homemade rim protection
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flag samwallace86
Posted: Mar 27, 2018 at 3:40 Quote
Been looking a cushcore for a while but stumped at the cost of it for a relativity simple thing...

Being a Civil engineer I saw the crack filer foam rods onsite and with them being closed cell foam I found out this is the same material as the cushcore

So I made a jig to slice the rods along their length at just less than half its diameter then joined the ends with duct tape

I tested it by fitting it to an old rim and throwing the rim off the concrete floor and various rocks with great, bouncy, results!

Works great and no noticeable weight difference
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flag Will1848
Posted: Mar 27, 2018 at 6:15 Quote
How dense is this stuff? I believe most of the rim protection systems us a pretty dense foam.
flag samwallace86
Posted: Mar 27, 2018 at 6:44 Quote
Will1848 wrote:
How dense is this stuff? I believe most of the rim protection systems us a pretty dense foam.

It feels very similar to the huck norris i have seen
flag zandeto
Posted: Mar 27, 2018 at 8:17 Quote
from what Ive heard huck norris is quite a bs, exactly because of the density. I believe cush core is a lot more denser. Huck needs to be changed often depending on the damage you do to it and thats one of the major downsides. If you hit twice at the same spot its practically useless. cushcore is more durable and lasting.
flag zeeman
FL
Posted: Apr 3, 2018 at 22:30 Quote
I love it. I hear that cushcore is a cool company and their design is great, but I can't justify the cost for me personally. It is good to see folks come up with ghetto versions.

EVA foam is what I plan to use. Its the stuff puzzle piece floor mats are made of. It ranges in density but my target is around 3 lb./cu.ft. I walked into this place and got a sample of 2" thick EVA foam which feels about right, but it is from a sheet, and sheets don't come long enough to make a whole rim's circumference, so if I were to rip it into a trapezoidal strip, I'd need to make 2 seams. This method could be customized to tire/rim width.

I have had a hard time trying to find EVA foam in a rod, especially longer than 6' which is less than a mtb wheel circumference. The best option seems to be concrete expansion joint material which Sam seems to be using...?

Anyone got links to the raw product here in North America? Possibly some kind of garage door gasket? Links to 2.5" and 3" backer rod, especially in pieces longer than 6' are welcome, although I definitely prefer the EVA foam expansion joint over regular closed cell pipe insulation and backer rod, which I hear takes up too much sealant and does not last very well with repeated strikes. I am thinking of ordering some of this stuff from MM systems. It may take a bit of modification to fit well.

Has anyone seen or tried a dual ply system where the densest part is like a huck norris, while a less dense layer sitting in the rim?

Door gasket (i wish it was symmetrical)
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flag zeeman
FL
Posted: Apr 18, 2018 at 10:41 Quote
Turns out EVA-200 is too expensive so I'm back leaning towards a sheet product that I'll modify into an insert.

For now, Armacell pipe insulation is working fine.
Short-term thinking pipe insulation not as durable as EVA foam. Plus size
Hacksaw grooves for air and sealant to pass by the ghetto mousse
flag ka81
Posted: May 18, 2018 at 15:45 Quote
What is the best width (diameter) of foam to make tyre insert?
50 mm would be good?

http://rktspb.ru/files/products/tmb_147703397085.jpg

Unsecure image, only https images allowed: http://rktspb.ru/files/products/tmb_147703397085.jpg
flag zeeman
FL
Posted: May 20, 2018 at 7:56 Quote
ka81 wrote:
What is the best width (diameter) of foam to make tyre insert?
50 mm would be good?

http://rktspb.ru/files/products/tmb_147703397085.jpg

Unsecure image, only https images allowed: http://rktspb.ru/files/products/tmb_147703397085.jpg
64mm? You want it to push against the sidewalls for maximum protection against angled strikes
flag ka81
Posted: May 20, 2018 at 11:26 Quote
zeeman wrote:
ka81 wrote:
What is the best width (diameter) of foam to make tyre insert?
50 mm would be good?

http://rktspb.ru/files/products/tmb_147703397085.jpg

Unsecure image, only https images allowed: http://rktspb.ru/files/products/tmb_147703397085.jpg
64mm? You want it to push against the sidewalls for maximum protection against angled strikes
uhm.... whaat?? )

ka81 wrote:
What is the best width (diameter) of foam to make tyre insert?
50 mm
flag zeeman
FL
Posted: May 21, 2018 at 17:37 Quote
You linked to a picture of backer rod. Pipe insulation may be superior to backer rod because when split in half it resembles cushcore, and I think this helps during installation. Assuming you run 2.5" tires then 64mm is about right. I used 3" pipe insulation split in half inside 2.8" tires, and it works trick.

All round profile tire inserts are poor design in my opinion.
flag ka81
Posted: May 21, 2018 at 22:43 Quote
zeeman wrote:
Pipe insulation may be superior
but pipe insulation has a hole inside, so how can it be perfect to keep tyre's sides?

Although it definitely will help during installtion.

p.s. sorry for bad english, not my native.
flag zeeman
FL
Posted: Jan 23, 2019 at 10:07 Quote
Repost/update:
For those of us who are concerned with $$$, the DIY version sure can take a beating. This week I removed my tire to patch the inside of a sidewall tear, and saw it was time to replace.

Anyone interested in the finer points of doing this without reinventing the wheel; I could post a step by step write-up.


500 miles of rim protection for 10 per wheel. This insert is ready for replacement.

78 circumference 650b wheel

Choose a pipe insulation with outer diameter approx equal to tire width. In the case of my 650b plus tire this 3.0 OD closed cell insulation slit in half to a semicircle x-section stuffs nicely into a 2.8 tire.

78 circumference 39 each half for 650b. You want it to fit snugly.

78" circumference (39" each half)
For 650b

Hacksaw grooves for air and sealant to pass by the ghetto mousse
Hacksaw grooves
flag Will1848
Posted: Jan 25, 2019 at 6:12 Quote
I’d definitely be interested in a write up with your experience and research of different options and what you found to work best. Save me some time monkeying around Smile
flag zeeman
FL
Posted: Jan 25, 2019 at 9:59 Quote
Okay great, I will work on that.
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