So there I was, trundling along 1 mile from home, when I noticed that my nearside front tyre was squeaking every time I hit a bump. Looked across and
there was my wing flapping more than was usual... so I stopped, removed the remaining bolt and stowed the wing away.
I think I'm going to have to copy LocoR1's solution:
(originally attributed to WorX, but now corrected!)
Description
It's the obvious answer as it stops the wing flapping and causing stress fractures - but it's a fair bit of work.
The alternative is to use clamshell wings... but I'm not sure I like them...
[Edited on 26/7/08 by David Jenkins]
LMFAO! Which one is Worx's solution again???? 
O
Well mine would be closer to the bloody Noddy car!!!
It's actually Dave's (LocoR1) Solution!!!
Steve
Oops!
Sorry to all - especially to Dave!
(Still can't see how the bearing holder is fixed into the wheel though...)
how you mounting it at present? mines just on with panel bond! but I may glass the inside!
The fixing between the wing and the bracket is fine (I used flexible epoxy glue, with GRP over the top). It's the bracket itself that's
suffering classic vibration-related stress fracture. This time it broke right next to the mounting bolt, which is sort-of understandable - everything
below is rigidly mounted to the upright, everything above is flapping about, so all the stress is concentrated in one small area.
Dave's external bearing and brace is probably the only way to stop the root cause, which is having 1Kg of GRP wing wobbling around on two bits of
300mm steel because it's only supported on one side.
It's usually the nearside that suffers the most, as that's the one that gets the pounding from roadside potholes and drain covers.
How many times have they broken now David? mine has broken 4 times, each time I have repaired and reinforced . Soon as I get a chance I will be making some new ones using metal twice as thick as the original stays and fitting new lightweight wings
I think that this is my 3rd breakage... I don't know about using thicker steel - I'm already using 5mm x 15mm strip! And the trouble with
reinforcing is that you just move the fracture point somewhere else... 
As I said earlier - I've either got to stop it flapping, or go to clamshells.
Anyone know at what speed the clamshells start to create 'interesting' aerodynamic effects?
[Edited on 26/7/08 by David Jenkins]
I've used 5mm strip. Works fine. The only issue is that you have to just bend it once. Any unbending and re-bending and it's time to make a
new one....
No breakage yet in about 1k miles....
Mine broke again (rear near side support at the weld between round and flat section) a few days ago when my wife & I were out for a run.
We had no tools with us to remove the wing and the only thing we had was a pair of pop socks in my wifes handbag which secured it enough but needed
several stops on the way home to re-tie. Had it welded and reinforced and it's back on the road.
Going to redesign over the winter.
Our first wing stays were made of perfect angles to suit the arches and welded together etc.
Then we made some more with additional strengthening and bracing fillets and they wore on the weld or just before again.
The set we've got now were heated up and then bent with some stilsons while still warm and toutch wood they've been ok. I think its like
work hardening or where the welds are that cause them to fail.
quote:
Originally posted by BenB
I've used 5mm strip. Works fine. The only issue is that you have to just bend it once. Any unbending and re-bending and it's time to make a new one....
No breakage yet in about 1k miles....
" When" I get around to making new stays I intend getting the wings as close as possible to the tyre without touching to reduce the amount of lift the wing creates as I suspect along with the potholes etc that may be a cause of breakages
Just come back to base after wing bracket breakage no 4,
Surely their is some-one who makes unbreakable stays for the cortina uprights.
This is costing me a fortune in new guards.
Kipper. aka Denis.
I made mine from 3mm strip but doubled it up by welding in a fillet over the joint to the tube, the tubes are about 15mm thick wall tube and can flex
a bit rather than being a rigid mounting point for the wing mounting strips. The wings are quite short and mounted very close to the tyres I also
heated the whole lot to red heat after welding to stress relieve it..I notice that the whole tube flexes rather than just the mounting strip and so
far they have lasted about 5000 miles.
Paul.
quote:
Originally posted by Scoobylav
How do you attach an externally mounted bracket ?
I haven't, but Dave has some in his photo archive
LINK
Not enough info, but it might start your creative processes!
I'm considering doing it a different way - I'll throw it to the forum once I've developed my thoughts a little bit.