Homemade Disc Wheel Cover | How To Make Your Own Step-By-Step

You’re probably thinking ’ooo lucky GTN, with your expensive disc wheels’. But Mark's disc wheel cover isn't just any old! It's a homemade disc wheel cover and cost under £30! Interested? Here's a step by step guide on how to make it!
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Now we know what you’re probably thinking ’ooo lucky you, with your expensive disc wheel’. But Mark's cover in this video isn't just any old disc wheel cover...this is a homemade disc wheel cover and all for under £30!
That’s a fraction of the cost of a regular disc wheel and it really works rather well. Interested? Well, here is how to make it!
If you enjoyed this video, make sure to give it a thumbs up and share it with your friends. 👍
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Watch more on GTN...
📹 Disc Wheel Vs Deep Section | Which Wheel Should You Race With? 👉 gtn.io/DiscVsDeep]
Music - licensed by Epidemic Sound:
Between The Lines (COE Remix) (Instrumental Version) - Elijah N
Boom Bap Jazz 3 - Da Tooby
I Follow Your Heartbeat (COE Remix) (Instrumental Version) - Tellow
Midnight Zenith - Luwaks
Niagara - Chris Shards
Still Broke - oomiee
Turn It Up (COE Remix) (Instrumental Version) - Mike Parr
Wildside - Splasher!
Photos: © Triathlon / Getty Images
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[@hellopsp180]

@GTN - can you do a video to compare this disc wheel vs more expensive ones. So we can see if our money is truly worth forking top dollar for premium disc wheels. Or can we make a DIY Disc cover and get similar performance. and of course would be good to see the discs compared to the deep section + box section wheels too.

[@mrmatthewking]

Short answer is there's no significant difference. It will probably be heavier but that doesn't matter much

[@markthrelfall3577]

I'm pleased you've asked... I'd like to give my homemade creation a little more airtime. I'll try to do this for you :)

[@AnvilAirsoftTV]

It’s within a few watts. I used to run a wheel builder disc cover on a felt TT 40mm alloy rim when I was racing. It can be quite heavy depending on the wheel you’re using. Only real downside is that you don’t get the whomp whomp noise :)

[@kubagornowicz]

@@Gideonkomen "No awe-inspiring, soul-crushing WHOMP! WHOMP! WHOMP!" :/

[@tonyy5482]

I used a cover for racing for several years. In the right conditions it makes a significant difference. I don't think extra expense would help. You might be able to buy something lighter (although covers can be very light, lighter than solid wheels even) but you likely wouldn't choose to fit a cover when a lot of climbing is expected. On the flat, any decreased acceleration due to extra mass is likely compensated for by momentum (angular momentum in this case) and sail effect. It can feel like you are an unstoppable train (make sure your brakes are good :D). BTW my cover was thinner, stretchy but shiny. If I made one, I think I would go a little thinner & lighter than 1mm.

[@brendanclemmens88]

Exactly how Zipp makes them in the factory.

[@bikerdude221]

#3:38 That is the longest 28mm length I've ever seen :D

[@markthrelfall3577]

bikerdude221 haha oh dear! Good spot. What was I thinking 🤔

[@bikerdude221]

@@markthrelfall3577 It's all good, certainly was a good laugh. Lets just say you did it to make sure people are attention :P

[@jamesExiledLegends]

It's British 28mm, not standard metric

[@Jeesus353]

@@jamesExiledLegends imperial millimeters

[@NicholasWoodley]

Hack or Bodge. Please send it to the GCN team for a verdict. 😂

[@Red-ju4mi]

Hacks. I wish you did a more semi permanent solution rather than taping it onto the wheel. Is that even legal or safe? Im sure on the velodrome taping it on wouldn't fly. How could you adhere it to a carbon rim without ruining it?

[@mrmatthewking]

Nice work, almost exactly the same as my build. Tips from my own experience: 1) you don't have to cut all the way through the ABS, just score it a couple of times and flex it, and it will snap cleanly. 2) use a metal skewer, heat it on a gas stove and you can melt fine holes through for the centre of your circle. 3) use an offcut edge of the ABS to make your giant compass. And use the giant compass to hold your knife to cut a really neat circle. 4) haircell ABS looks really nice with the texture, no scratches. 5) I didn't worry about gluing, just taped the joint on both sides. 6) I locked out my lowest gear with the limit screw to prevent the derailleur rubbing on the cover. Still fine for flat races.

[@samuelhopely4853]

I've been wanting to make one of these for genuinely years, and there's never been enough good advice online. This helps tremendously. Thanks so much!!

[@omerfurtun4115]

Just googled Haricell ABS and it doesn't look very aero with it's textured surface. I remember from the GCN video in the wind tunnel where even gaffer tape+cardboard for a rear disc was found to be not very aero.

[@mrmatthewking]

@@omerfurtun4115 textured surfaces are often more aerodynamic than smooth due to boundary layer effects. See the dimples on Zipp wheels for example. I can't say for certain which way would be better without extensive testing, but it would be possible to try by mounting the cover inside out (the other side of haircell ABS is smooth). Either way the difference would be extremely small.

[@markthrelfall3577]

Thank you. Great tips

[@scottmichaels6624]

@@mrmatthewking: Dimples and rough surfaces are used to delay separation in high adverse pressure gradient situations, not something applicable to the surface of a disc wheel in almost any circumstance (they are basically flat, so flow will either separate or it won't). It's much more likely that the increased skin friction drag (particularly at the top of the wheel where the surface is essentially travelling at twice the bike speed, so 100kph+ on a fast flat course) would significantly outweigh any possible profile drag improvements by reducing separation (source: I'm an aerodynamicist!). I could easily be wrong, but that's my gut feel.

[@anthonyescareno]

Good video, mate! Here is another video idea: Test this DIY disk wheel vs. a traditional disk wheel. Let’s see if there is a measurable difference in performance.

[@someguy9520]

Have been waiting for that video to finally come out. Mark seems like he likes to do stuff like that. And since triathletes have to finance three different sports, making a diy disc wheel cover always seemed alluring for the budget-minded

[@markthrelfall3577]

Thanks Calvin. I'm glad you enjoyed it

[@bobbysilver272]

I made a disc cover for my rear wheel last week. So far this season I have had 5 times between 23m 17s and 23m 42s in my local 10 mile TT. This morning I did a 22m 51s using the rear disc wheel I made.

[@gtn]

Awesome work!

[@southpawairsofter]

where did you get the plastic?

[@bobbysilver272]

@@southpawairsofterAvailable on ebay but I got it from bayplastics.co.uk Order: black smooth abs sheet I bought a sheet 2500mm x 1250mm x 1mm and they cut it into 4 parts for me so could be sent through the mail. (each cut piece was still big enough for a wheel.)

[@karlnorgaard6077]

I have a loop I do weekly, about 40 min. First ride with disc I shaved about 3 mins off average.

[@ericoschmitt]

You can do a permanent disc with expansive foam (on a cheap wheel), then sand and add vinyl adhesive (or resin+sand+paint). This method makes whooshh whooosh sound! And doesn't add much weight. Better build a wheel with internal nipples for that, or no more truing will be possible... If you choose the right alloy rim it can easily be under 1kg for a cheap disc wheel!

[@markmarrs3627]

Did this back in the late 80's with Kevlar. It worked great. I cannot remember the amount of improvement we got but it was comparable with the disc wheels at the time.

[@bizzehdee]

Do you have a link to where you bought the ABS plastic from?

[@xGshikamaru]

Probably one of the best videos you've ever made thanks Mark!

[@karlnorgaard6077]

Thank you! Can't believe I found a video on this. Im a GCN viewer, but after this intelligent, thorough piece, Imma check y'all out more often. Most older roadies, myself included, are fairly mechanically inclined, and love DIY. I make some of my own parts like quill stem adaptors, allowing modern bars and stems on vintage steel bikes. Have also made a few different handlebars myself. I've made Q-factor out-spacers for my pedals...all sorts of things. But I've been thinking of doing a rear disc. Thought of fiberglass mesh or window screen with varnish basically, a few different ideas have crossed my mind. But I like this one. And forgive me, I always think of TT riders as kind of an elite demographic, solving most problems with their credit cards. Pleasantly surprised to come across this video. I've built up a freewheel single speed time trial bike and on its first real highway ride today, got thinking about a cheap rear disc. I may do slightly different but great starting point for me. Thanks again.

[@matthewroberts1255]

There is so much that I appreciate about this. If after your tests you conclude the performance is worth the expense, I'm in

[@shaneporteous1310]

30pound cover on a $10000 bike, seems about right :P

[@markthrelfall3577]

Haha... I spent all my money on the bike though ;)

[@shaneporteous1310]

@@markthrelfall3577 don't we all 😀😁🤣

[@cesar31ms]

So he has a ten thousand bike. It saves on what can be done at home or cheap with the same effect. I thought it was really cool and I'm going to do it here in Brazil. But with PVC sheet. hug

[@shaneporteous1310]

@@cesar31ms make sure you share the results.

[@enzoocampoiii2881]

more lighter cuz he has one liver left lmao.

[@tonyy5482]

I bought and raced a stretchy, shiny wheel cover in the USA for less than £30. I still have it; still usable. It worked very well, esp. in cross winds. It used wire hoops at circumference, held in place by removable black plastic clips, that clip on the spokes and the 2 wire hoops. Looked good too. Lenticular (i.e. lens shaped) solid wheels like this exhibit somewhat different characteristics to flat solid wheels. They act like a sail in crosswinds :) Adds weight though, so not great for up hill.

[@4846maxt]

we need testing !!

[@markthrelfall3577]

James Tu 😉 I’m glad you’ve asked

[@JoshuaTootell]

Some nice TT testing would be great!

[@bingrusginckle]

The real disc trick is to use 3M car wrap vinyl to cover the wheel, since you can just pull it into tension and trim it around the brake track, so it’s super aero and also very very lightweight, adding only 30g to my rear

[@gkmadkorek]

pics or didnt happend :)\

[@robertmuckle2985]

Prove your theory please...in photos!

[@nitrouspeed3583]

Tor Do you think regular heavy duty vinyl would work? Or is the adhesion from the 3M vinyl necessary? My dad owns an advertising company so we have a bunch of extra billboards & I want to make a disc out of the eye of a Despicable Me minion.

[@bingrusginckle]

Nitrouspeed Unfortunately I was relying on the vinyl sticking to the edge of the brake track, so I don’t think it’d be very possible

[@andy-the-gardener]

one caveat is monocote shrink wrap stuff can potentially warp a wheel. i bought a recumbent bike with the rear real wheel done with vinyl wrap and it ran very untrue. but i did not know why. at later date i took the wrap off, because i wanted to fit a rear brake and he wheel was a lot straighter

[@stephenfischer5322]

Great tutorial on this!

[@scottmcguinness3942]

Great work... did similar on my 8y/o sons bike for his first triathlon! Using carbon look automotive vinyl over the plastic is the best way to finish it off.

[@coachrobwille4176]

Cool how did he do in the race ?

[@borisb.5024]

Consider using a push pin for the center, and attaching the string as low as possible on the marker - that should make the job a bit easier.

[@ahrkricardo7013]

If you're having trouble with the string, you can use a lengthwise cut cardboard with two holes. That way you get less unnecessary movement and a more accurate circle. Just make sure the cardboard touches the surface.

[@LewisRawlinson30]

I made custom disc wheel covers 2 years ago. You can make them lighter if you use 0.5mm HIPS instead of 1mm ABS.

[@markj01495]

Would you have a link for the sheets please.

[@markthrelfall3577]

Awesome

[@markj01495]

@@LewisRawlinson30 thank you.

[@eugenius1226]

Good job Marc

[@Pienimusta]

Seems super professional when compared to Neil's homemade aero wheels ;D

[@markthrelfall3577]

Pienimusta haha I’ll pass that on 😂

[@ahmadbassem2077]

Yaayyy gtn arts and crafts

[@simoneallosio3052]

Fantastic!!!💪💪

[@enricoobispo4085]

Thank You Sir For Sharing.

[@christianlagioia]

a tip for drawing the circle: hold the string as low as possible , or get a ruler or a piece of straight something, tape 1 nail to 1 end and the pen/marker at the desired distance.. good luck :)

[@awsomeme31]

Him: it’ll only cost 30 pounds Also him: pulls out deep section enve rims

[@gtn]

Haha good spot - but it doesn't take away the point that anyone can do this to any bike 🙂

[@hayleyupton2815]

Hi we've just seen the cover but we're did you get the right size plastic from Cheers

[@drumfun100]

Great vid...What we need next is how to make your own decals!

[@markthrelfall3577]

;) They might be coming

[@digbysirchickentf2315]

I used to make wheels covers as a kid using the heatshrink wrap that they sell to cover the wings of RC planes. Weight around 20 grams.. Pretty easy to apply, but it covers up the brake track, so only good for fixed wheel bikes.

[@furstylist]

Could you share how you did it? I want a wheel cover to cover the spokes of the bicycle so when my dog runs alongside it his paws can't get trapped in the spokes.

[@digbysirchickentf2315]

@@furstylist It was a long time ago cant rember the product name.., I the think the wrap got sticky when you heat it with a hairdrier, so i just cut a circle to cover the wheel and made sure it was stuck to the brake track, (you cant use rim brakes when its on) and then shrunk the middle taught. There are wheel covers that you can buy though which tie onto the spokes, much heavier solution of course.

[@emrecetin8743]

It's a very good chanel. I like it.

[@aaronfuksa2047]

I like the idea of plastic push pins, or plastic mating bolts to hold disks together near the rim edge. Some clips or bread ties/zip ties if i recall keep it firm anywhere else. I don't trust tape. Been wanting to do the rear wheel of e-bike, but after i get belt drive sorted out.

[@Alex-kr7zr]

Nice idea, one could make some bolt adapters using a 3d printer. Thinking about ways not needing to take the cassette off as well.

[@adityad9700]

#GTN you guys should do a comparison video between the wheel with the disc cover and without the disc cover. Also, keep up the good work guys. Cheers!

[@markj01495]

Could you provide a link to the ABS sheet please.

[@officialclownbusiness7788]

Cool! I might try to make one that is painted to look like a Cragar mag or something.

[@BombedNevada]

If you add a spiral paint job, as you ride those watching will suddenly be hypnotized.

[@gtn]

🌀🌀🌀🌀

[@markthrelfall3577]

I actually toyed with the idea of doing that

[@officialclownbusiness7788]

"My Hypno-rims!" -Carl

[@super71x]

I did it at home also after watching your video, greetings friend

[@sofiatorres3332]

Looks great! 👍 🤔Could you make one for a 20" BMX wheel?

[@coachrobwille4176]

Cool video

[@cristianguerrero9683]

Nice!

[@erykszczepaniec7162]

I’m currently making this cover and I got one question. I was thinking about that , with real disc wheel as well . So, can you change inner tube , with this cover on ? . I would love to use it on my next race

[@derf9465]

Like the wheel covers on cycling hockey

[@chrisking5948]

Whats the best material/size too use for this?

[@derzkoeradio]

Is it possible to use heating dryer for cone shape?

[@barbodhashempour6188]

I have a question. What is the name of website that you bought ABS sheets from? If you have any other websites to suggest, please mention them.

[@thepuremotivemovement]

It would be great if after it's finished, cover it with a Vinyl Warp to cover the slit. What's cool about this is that there are a lot of Vinyl Warp color options out there to make it look premium.

[@369_narsimha_keshav6]

Should I do with my alloy wheels ?

[@simedinson984]

wouldnt it be better to fasten non drive side with tape as the casset will hold the middle part pretty well on the driveside so no need to tape over the spokes

[@coachrobwille4176]

Good point

[@jochem1986]

Great idea! But I think the pen-pen centering isn't a good method. You can see the inner pen tilting, which can easily add a centimeter to the radius. Also, if you don't keep both pens rotating with the wire, the wire will twist around the pen, making the radius smaller again. You could measure up a compass template from foam board, and tape both pens inside there, to get a perfect rigid compass and a really clean circle. Also, it seems really important to get the slither size just right. You can see on your drive side, the slither is too wide, making the disc too conical, and subsequently the cassette presses on the disc, giving it an S-shaped section, where it should be straight. I think it's possible to create a pretty accurate measurement template for the discs. I'll give it a go and let you know.

[@jimbo9030]

To cut a perfect circle use the same string technique but with a scalpel on the end instead of a pen 👍

[@jaysonplacencia2285]

What is the black board do you use?

[@fgv3357]

Also i would like that comparison video vs fabric disc wheels that Ian R suggested.

[@danielechiappa1046]

I want to give it a try but strugglin finding that 1mm ABS. Can someone share some link? I just found 200x300 mm sheet that is clearly too small.

[@lanemonroe7257]

Would acrylic work instead of abs plastic?

[@woody9382000]

Comparison video, please. Nice demo.

[@olasonn]

Can't find ABS where I live, but PEHD is plentiful. Could that work?

[@BorgyManotoyOnline]

Is this compatible with disc rotors? TIA

[@miguelmedal8465]

Que tipo de material usastes ? como se llama ?

[@jejedjorkaeff2379]

Nice Job ! :) Can you do a video like "How to choose your wheels?" That would be very helpfull to upgrade my bike ! Thanks

[@cyclingschannel]

You go faster with this? How many kmh you gain at same power?

[@panzerveps]

At same power output, about 2-3 km/h compaired to normal wheels.

[@LulepeLP]

You can't make a flat call, it depends on the wheels you're using before, and it highly depends on the speed you're going at, also, your frame aerodynamics play a role here. Many factors to view, but it's a decent improvement.

[@markthrelfall3577]

I’m glad you’ve asked 😊 I plan to do just that

[@cbyod]

@@markthrelfall3577 can you use gorilla glue?

[@deNudge]

@@panzerveps That's massive!

[@maruchan368]

What type of pvc did you used?

[@anthonymarin5165]

The cement will make the wheel vibrate thus loosing power. I would've went with superglue inside the seem.

[@noahalso]

Please let me know the source for the ABS you purchased. Thanks.

[@Marcosrc98]

Where can we buy that ABS laminates?

[@briggsclassicrider]

What's the exact measurements of the ABS plastic that you use?

[@derf9465]

Is that contact adhesive? Put some on each side, wait till tacky and join together.

[@airguillo31]

now the question. Would you use it on a race?

[@karlnorgaard6077]

Hack of course. I'm so stoked on my new DIY wheel cover. I think my approach was superior, but I thought about it for over a year.

[@Kid_codmobile]

Can We used Acrylic Sheet instead of ABS sheet??

[@MrIDNumber]

does someone have a link with the ABS plastic for sale?

[@JonathanWhoever]

Reminds me of the old Uni disk kits. Basically to pvc coated circles of fabric and two aluminum hoops for the outer circumference .

[@cesarmercado1321]

Como se llama el material que usa para hacer los platos de la bici

[@davidt.berghold4700]

It sounds quite wobbly in the first seconds of the video. How is the sound? Will get it loose?

[@mikexhotmail]

that was his own voice effect LOL

[@markthrelfall3577]

Yeah...haha. Sorry I was joking around and making the noise myself. It also didn't help it was very wet and a bumpy road

[@salsagonzales640]

Now please: how to make deep section wheels?

[@fenkie]

Link to buy the sheet of abs plastic ?

[@ppierreeliott853]

on what site did he bought the ABS sheet ?

[@revvingrebel8213]

any tips for disc brakes covers ?

[@miguelsaez340]

velodrome comparison please hahahah

[@whosurdaddy418]

How do you inflate the wheels back?

[@ronortiz5417]

what is a material name that wheel cover ser please tell me😥

[@ImTrendArts]

where can i get plastic for the cover in Canada it impossible

[@johnsalvesen4119]

where can i find plastic sheets that big 1300X660mm 1mm thickness

[@tinhecaalbatroz5394]

Great idea! Do more DIY videos! Can you do something with recycled materials? I once made a mud guard from a plastic pack of soap 😊.

[@markthrelfall3577]

Tinheca Albatroz superb idea

[@kamilniemczuk2920]

How much does it weight?

[@pm3t385]

How the heck did you get that cannon track bike???

[@ton-cta1270]

ใช้ แผ่นอะไร ทำฝาครอบล้อ ครับ

[@iliaspanagopoulos3769]

can you reply the link to the plastic or tell me what to search for to buy it please

[@stingingmetal9648]

And you have a clean palate to put cool stickers or patterns. L.e.d's inside.

[@arcsatt1]

Why dont you do the front tire also?

[@lanuzodominicmariona.5361]

What is the name of the plastic that you used?

[@jeremycanham9537]

Amazing video! Where did you get the plastic from?

[@Northwindbreeze]

He said online

[@johnpaulcantera8076]

What plastic you use?

[@tkdnewport]

Easiest way to create a perfect circle, piece of batten timber measure your required length from center to edge, drill small hole for center and larger whole for sharpie to fit in, rigid and solid circle in one :) only dawned on me after I tried to 2 pen method (what a nightmare).

[@ashwinmandan5]

If you've ridden a real disc wheel then you'll know that a disc wheel will accelerate more than a deep section wheel Reasons that a factory disc wheel is a solid disc, thus having a lower Moment of Inertia than a ring Good Job Mark, for the disc cover thing, might as well try it on my bike

[@carlosjosegarciadelpozo6103]

Where you buy the plastic

[@michel852]

Thank! Made in Brasil/ Florianópolis- Praia dos Ingleses- Cervélo p2 (2010)

[@lucasweber8880]

Is there also a methode to make your own deep section wheels for shallow ones?

[@ericoschmitt]

Expansive foam. This is the way I can think: You gotta add some cardboard to both sides of the rim, then apply foam to that. Mask the braking track before that. To make sure it doesn't expand too much inwards into the spokes you can cut many pieces of cardboard to fit between spokes, and make holes in them to apply the foam with the straw. Find your way to remove the cardboard, it will be sticky. Then lots of sanding, then you can apply some resin over it, sand and paint. Or skip the resin step and use vinyl adhesive over it, there are some that even look like carbon. You will have to actually sculpt the shape of the rim... It will give you lots of work due to spokes being there. And then you cannot access the nipples anymore for truing unless you build the wheel with internal nipples. Better do your first attempt with a cheap wheel. I tried and failed the first time, but it wasn't too hard to remove everything with a knife and patience, so you can try again.

[@lucasweber8880]

@@ericoschmitt Thx

[@ericoschmitt]

@@lucasweber8880 But really think if its worth. There are very high quality and affordable rims from chinese manufacturers such as LightBicycle, which I own a pair of 56x30mm rims and they are absolutely perfect in every way, plus they are cheap, even cheaper if you buy rims and build.