FastTt TT Aero Bar User manual

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FastTT Aero Bar Installation Guide - TT v8
[Designed for Speed]
Carbon Aero Bar
INSTALLATION GUIDE
www.FastTT.bike
MODEL: TT Aero Bar

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FastTT Aero Bar Installation Guide - TT v8
Congratulations on purchasing your FastTT Aero Bars!
The following pages will guide you through the installation process.
Please read the instructions from start to finish BEFORE commencing installation.
It is important to follow the installation sequence.
You WILL require a second person to assist with marking and holding. Installation might take
around 2 to 2½ hours.
TOOLS REQUIRED
• Fine tip felt marker pen
• Power drill
• 2.5mm metal drill bit (cobalt recommended)
• 6mm or 7mm metal drill bit, depending on bolt diameter (cobalt recommended)
• Torque tool
• Hacksaw or Dremel cutting tool
• Electrical tape or masking tape
• Spirit level (if measurement jig not available)
• Measuring tape
UCI/ISO CERTIFICATION
FastTT aero bars have been tested and certified to the
ISO-4210 standard required for use in UCI sanctioned
events. The certification sticker with test reference
number is on the underside of each bar.
DO NOT remove this sticker.
IMPORTANT NOTE!
Installing FastTT Aero Bars requires a little more technical knowledge and attention to detail than
fitting standard bolt-on TT/Tri bars. We STRONGLY RECOMMEND using a bike mechanic or bike fitter
that has experience with TT/Tri bikes and is familiar with setting up to meet UCI regulations.
If you are not confident using workshop tools or carrying out technical repairs to your bike, please
have a qualified bike mechanic or bike fitter install your FastTT Aero Bars. They are a big investment
and we would not like you to damage them through incorrect installation (and void your warranty).
INTRODUCTION

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FastTT Aero Bar Installation Guide - TT v8
SECTION A - GETTING STARTED
CONTENTS

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FastTT Aero Bar Installation Guide - TT v8
MEASURING YOUR CURRENT SETUP
Before you start installation, take a full set of measurements of your existing bar setup for later
reference and UCI compliance.
Key measurements to take are:
Length from centre of bottom bracket to bar
tip end (including the shifters).
Height difference from top of elbow cup
(measured at the fore/aft centre) to top tip
of shifter/bar end.
1. Height of top of elbow pad from the
ground (measured at fore/aft centre).
2. Top of shifter tip from the ground.
SECTION A - GETTING STARTED

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FastTT Aero Bar Installation Guide - TT v8
Distance between outside edges of elbow
pads. Note the distance where you
measured relative to the bottom bracket so
you can repeat the same measurement for
your FastTT bars.
Width between shifter tips or bar ends.
Once measured, remove your old extension bar and shifters, but leave the brackets mounted
to the base bars (if applicable). Disconnect shifter cables.
Elbow pad measurements for UCI
compliance should be taken at the fore/aft
centre of the pad.
Please refer to the UCI website for measurement rules based on rider height:
https://www.uci.org/equipment/bh2JJzw1eB0n876rX2iB1
SECTION A - GETTING STARTED
SECTION A - GETTING STARTED
SECTION A - GETTING STARTED

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FastTT Aero Bar Installation Guide - TT v8
TRIMMING THE BAR ENDS
Hold the bar end as you would when riding,
resting the bottom of your hand on the top
surface of the extension. It should fit snugly
with no gaps between the base of your hand
and the bar extension.
Measure how much bar end you require to fit
your shifter, taking into account the extra length
the shifter adds to the bar.
Mark the top of the bar ‘A’ including shifter
body length. Deduct the length of the shifter
from ‘A’ and mark position ‘B’. The difference
between ‘A’ and ‘B’ should equal the length of
the shifter (excluding the insertable section).
NOTE: Shimano Di2 is only indicative of a shifter and is not a recommendation or endorsement.
Your bars have a removable measurement guide
sticker for accurate and consistent marking.
Mark the position to be trimmed ‘B’ with a
marker pen. Use a hacksaw or Dremel cutting
tool to trim off the unwanted bar end.
MEASURE TWICE, CUT ONCE!
SECTION A - GETTING STARTED

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FastTT Aero Bar Installation Guide - TT v8
Trimming the bar ends to the correct length is essential for accurately measuring the UCI
dimensions and MUST BE COMPLETED BEFORE MOVING TO THE NEXT STEP.
Examples of various shifter types fitted to the aero bars, showing different bar height/length
setup options to suit individual athlete preference
SECTION A - GETTING STARTED

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FastTT Aero Bar Installation Guide - TT v8
INSERTING THE ELECTRONIC SHIFTER CABLES AND INSTALLING THE SHIFTERS
The shifter cable must be drawn through the internal bar cavity and out the pre-drilled exit
hole. A shifter draw wire has been supplied for this purpose.
Remove the rubber grommet and insert the black end plug of the draw wire into the hole and
feed it through the bar body until it exits out the bar tube. If necessary, use the curve of the
cable to assist in guiding the draw wire into the bar tube.
Plug the shifter cable into the black tip of the draw wire as shown below and carefully pull it
through the bar so that it appears at the rear exit hole. Pull it clear of the rear exit hole and
unplug the shifter cable from the draw wire.
• Di2 - firmly insert the black tip of the draw wire into the Di2 plug connector
• SRAM – firmly insert the silver SRAM cable plug into the black tip of the draw wire
Di2
SRAM
SECTION A - GETTING STARTED
Black
end
plug
SECTION B - CABLE INSTALLATION FOR ELECTRONIC SHIFTERS
Di2
SRAM

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FastTT Aero Bar Installation Guide - TT v8
Slip the rubber grommet over each shifter wire and re-insert into the rear exit holes in the bar.
Insert the shifters and tighten according to the manufacturer’s instructions.
SECTION B - CABLE INSTALLATION FOR ELECTRONIC SHIFTERS

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FastTT Aero Bar Installation Guide - TT v8
Remove the foam elbow pads. Place the bars onto
your existing mounting pad/base in the position that
matches your original bar setup (refer to the original
measurements you took in SECTION A - GETTING
STARTED).
For ultra-narrow setups you can trim up to 12mm
off the inside edge of the paddle on each bar with a
Dremel cutting tool or hacksaw. Do not cut this
unless you absolutely need the extra space for an
ultra-narrow fitment. The paddle area is designed to
smooth the flow of air under the bars and away
from the chest area, so unnecessary removal will
negatively impact aero performance.
Carefully mark the area to cut with masking tape
before cutting. Trim the foam pad to match.
If you are using FastTT spacers or angled
wedges, bolt the spacers/wedges to your
mounting base from the TOP SIDE.
Trim off
12mm max
SECTION C - MEASURING FOR INSTALLATION

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FastTT Aero Bar Installation Guide - TT v8
SETTING UP FOR UCI RULES
For UCI legal setup you need to measure the distance from the centre of the bottom bracket to
the tip of the bars or finger hook. You will also need to measure the height from the centre of
the elbow pad to the top of the bars or finger hooks. If you don't have access to a measuring jig
you can use a vertical wall as suggested in the diagram below, but ensure the wall is exactly 90°
vertical (check with a spirit level).
Please refer to the UCI website for measurement rules based on rider height:
https://www.uci.org/equipment/bh2JJzw1eB0n876rX2iB1
SECTION D - MEASURING FOR INSTALLATION
SECTION C - MEASURING FOR INSTALLATION

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FastTT Aero Bar Installation Guide - TT v8
Your aero bars have a removable marking grid sticker on the underside to assist with
measurement accuracy and consistency.
Trace around the outline of the mounting bracket/spacer/wedge on both bars from below with
a marker pen. The available mounting base area is approximately 93mm x 32mm (hole centre
to hole centre).
Remove the bars and the mounting spacers/wedges from the bike and mark the REAR
mounting hole on both bars. Do not drill mounting holes beyond the black holes marked on the
grid as the mounting post should not protrude beyond the flat area.
SECTION D - MARKING AND DRILLING THE MOUNTING HOLES

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FastTT Aero Bar Installation Guide - TT v8
Start by drilling a 2.5mm pilot hole for the REAR bolt in each bar from the UNDERSIDE of the
mounting base, using the marks that you placed in the previous step as your guide. Check
carefully to ensure that the marked positions are the SAME ON BOTH BARS before drilling.
Once drilled, carefully cut out a 10mm square of the Velcro around your rear pilot hole. Only
cut deep enough to cut the Velcro, trying not to gauge the carbon (a small score line in the
carbon will not affect the strength of the bar). A sharp craft knife, box cutter or scalpel is
recommended.
Using the 2.5mm pilot hole as a guide, drill the rear mounting hole - use 6mm drill for M5
(5mm) screws, 7mm drill for M6 (6mm) screws.
Drill gently and carefully to avoid carbon splintering where the drill exits the hole. Drill the hole
at a similar angle to your chosen mounting angle. If you notice carbon splinters around the
hole, deburr them as much as possible before fitting. Refit your spacers (if applicable) and then
bolt the bars to the bike by inserting the mounting screws through the REAR holes.
SECTION D - MARKING AND DRILLING THE MOUNTING HOLES

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FastTT Aero Bar Installation Guide - TT v8
If you are using spacers/angled mounting wedges, you will need to purchase stainless steel or
zinc coated countersunk Allen head screws of an appropriate length and thread diameter (M5
or M6) to suit your setup. Most countersunk screws are available from a nut and bolt supplier.
We stock a comprehensive range of long mounting bolts:
https://www.fasttt.bike/product-category/mounting-bolts/
Lightly tighten and adjust the inwards/outwards
angle to your preferred position. Once this position
is established, mark the hole for the FRONT mount
screw onto the grid sticker from BELOW..
Remove the bars and spacers from the bike and repeat the drilling process you used for the
rear hole (drill 2.5mm pilot hole from bottom side, cut out 10mm Velcro, carefully drill a 6mm
or 7mm final hole, depending on screw thread diameter).
FastTT spacers and angled wedges have a
channel in the rear to fit the shifter wires.
To route the shifter wire you will need to drill a 6mm hole in
the bar mounting pad. Measure the position of the hole
carefully to align with the shifter wire channel. Drill a 2.5mm
pilot hole from BELOW, cut out a 10mm square from the
Velcro, then drill a 6mm final hole.
Refit the bars to the bike and tighten lightly. Recheck your measurements to ensure UCI
compliance.
Feed the shifter wire through the hole you just drilled and press it firmly into the channel in the
back of the wedges/spacers. It will fit snugly.
SECTION D - MARKING AND DRILLING THE MOUNTING HOLES

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FastTT Aero Bar Installation Guide - TT v8
If you wish at any stage to change the
setup of your bars and require new
mounting holes, it is safe to drill additional
holes in the base pad, provided you allow
at least 10mm space between any holes.
This will retain the integrity and strength of
the carbon fibre. If you are at all uncertain
regarding drilling additional holes, please
email us - [e-mail].
For a more extreme setup you can add our Extender Plate to provide additional position
options.
SECTION D - MARKING AND DRILLING THE MOUNTING HOLES

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FastTT Aero Bar Installation Guide - TT v8
If you are using FastTT angled wedges, always install
them with the countersunk chamfer facing up. If you
require the bars to be higher you can use our spacer
kit for additional height.
If installing angled wedges AND spacers, the wedges should ALWAYS be installed at the TOP of
the stack above the spacers, and flush against the base of the aero bar.
On FastTT spacers, the round locator domes will ensure that the spacers align perfectly. If you
are only using our mounting spacers and not the angled wedges, then you should file off the
round locator domes on the TOP SPACER to ensure a flush fit against the bar or Adjustable
Angled Riser. Complete the marking and drilling process.
SECTION D - MARKING AND DRILLING THE MOUNTING HOLES

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FastTT Aero Bar Installation Guide - TT v8
Be careful to not stack the mount post structure too high, especially if you are using M5
(5mm). For tall stacks we recommend using a bridge to provide lateral support.
If you want to raise your bars higher, you can also fit the steerer spacers supplied with your
bike.
Fully tighten the Allen screws to the specifications of the bike manufacturer (maximum torque
of 5nm). Apply a small amount of thread lock to the screws before fitting. Re-install the foam
elbow pads.
For detailed mounting information we recommend you review the Universal Mounting System
Installation Guide is available here - https://www.fasttt.bike/guides/
IMPORTANT!
Whilst every care has been taken to ensure the information in this installation guide is accurate
and correct, UCI regulations and rules are reviewed and updated from time to time. It is the
customers sole responsibility to ensure that you are familiar with the latest rules and
regulations regarding the use and fitment of aero bars and associated components. UCI
technical equipment rules are available here:
https://www.uci.org/equipment/bh2JJzw1eB0n876rX2iB1
Your bars have been supplied with the correct computer mount as ordered. Place your
computer onto the mount, loosen the screws underneath, adjust the computer position to
suit, and tighten the screws. If you change your computer brand you can purchase
SECTION E - ADJUSTING BAR HEIGHT

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FastTT Aero Bar Installation Guide - TT v8
replacement inserts that will fit directly into your existing bars by simply removing the screws
and the insert.
SECTION F - ADJUSTING THE COMPUTER
IMPORTANT SERVICE NOTE!
After a few rides we recommend that you check and retighten the mounting bolts on your FastTT
Aero Bars. The bolts can become slightly loose after initial riding due to natural bedding in of the
bolts into the carbon mounting base. This can potentially cause a small amount of lateral movement
in the bar. If this occurs, please retighten to a maximum of 5nm. We also recommend applying a very
small amount of thread lock to the bolts before refitting them. If at any stage you notice lateral
movement of the bar you should retighten the bolts.

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FastTT Aero Bar Installation Guide - TT v8
WARRANTY
FastTT Aero Bars are lightweight carbon competition units. In the event of a fall or harsh
impact, please check the bars carefully for any visible damage. Whilst carbon fibre is
exceptionally strong, it does not tolerate impacts, and damage that is invisible to the naked
eye can occur. This could result in unexpected breakage and injury, even death. If in doubt,
please have your bars checked by a reputable carbon repair company.
The manufacturer (Bold Horizon Ltd t/a FastTT) assumes no responsibility or liability for any
injury, loss or damage caused as a result of using this product under any conditions. FastTT
Aero Bars are supplied with a 24-month manufacturers defect warranty. Any damage caused
by misuse, incorrect installation, modification, accident, or any other cause is not covered by
the manufacturer’s warranty.
In the event of a warranty claim the manufacturer reserves the right to replace, repair or credit
the full purchase price excluding shipping (where applicable). In the event of a replacement or
repair, the cost of returning the unit to the manufacturer will be paid by the customer. The
manufacturer will pay for shipping of the repaired or replacement unit to the customer.
SPECIFICATIONS AND INSTALLATION INSTRUCTIONS
Specifications and installation instructions are subject to change without notice. To the best of
our knowledge, all information is correct at time of publishing The manufacturer is not
responsible for changes to UCI technical regulations. It is the customer’s responsibility to
remain informed of any rule changes and to make the necessary changes to bike setup for
compliance.
CRASH REPLACEMENT COMMITMENT
If you're unfortunate enough to have a crash and damage your FastTT aero bars where they're
no longer safe to use, send them back to us and we'll replace them with a brand new set at
50% off the current retail price, including free shipping. It's tough enough crashing, but at least
we can help a little to ease your pain.
Contact us via email: [email protected] or message us on Instagram: @fastTT.bike
Copyright © 2022 FastTT - The Sports Product Division of Bold Horizon Ltd
SECTION G - WARRANTY AND DISCLAIMER