Zen Wheels Project

Convex Front and Rear Discs 3-Spoke Front and Rear Wheels Flat Rear Road Disc

In 2005, BikeNZ identified the need for high performance wheels for their elite track and road time trial program.

The project began with a review of data from aerodynamic testing on BikeNZ’s wheel inventory in 2004, this earlier work was done to determine the best wheel combination to suit the TK-001 frame.

The review identified the best wheels to subject to extensive aerodynamic and mechanical testing. Flat, convex and stressed skin (diamond) disc wheels, as well as 3, 4 and 5 spoke front wheels were then tested. In aerodynamic tests, both linear and rotational drag was measured. A measure of rotational drag was vital in assessing spoked wheels, as rotational drag makes up a significant portion of the total drag of a spoked wheel. Mechanical testing was based around weight and stiffness.

Once characteristics or each wheel concept were understood a total of seven prototypes were created (two disc wheels and 5 front wheels). These prototypes were then aerodynamically tested at the University of Canterbury wind tunnel.

The prototype Zen convex disc and 3-spoke front wheels produced excellent results, exhibiting lower drag than any other comparable wheels in aerodynamic testing.

In parallel with aerodynamic testing and development significant effort was applied to structural design, a number of innovations resulted. Integrated carbon rims and hubs reduced rotational mass giving quicker acceleration, and the use of high modulus carbon resulted in increased stiffness and further reductions in weight.

Production tooling was designed and produced in aluminium on CNC machinery. Materials were sourced from around the world, predominantly from the aerospace industry. Several materials were unavailable and were developed in house.

This project represents the most extensive and exciting R & D program to date. It has encompassed everything from mechanical design and construction processes right through to material development. And the results have been outstanding, Zen wheels are lighter, stiffer and have less drag than the world’s best. And are proven in battle with a medal at the recent 2006 Commonwealth Games in the teams pursuit.