AeroJacket Install Experience Needed

Josh Church

Finally got the wheel builder jacket in and put it on no trouble. My question is, how tight is it between the cassette and spindle/hub drive mechanism when all is done?
I know the website suggests trimming the hub hole if needed. Here are some pics of mine:


Has anyone else experienced this and/or how close does your aero jacket and large sprocket get? 

Attila Matyas

Under load you might get some rubbing in the big sprocket.  I'd put it on the bike and run it through the gears first in a repair stand and then again on the road.  For me it's sometimes smooth in the repair stand but once you apply force to the gears on the road it suddenly rubs so good to test both and trim as needed.

Josh Church

@Attila Matyas thanks for the quick response. I'll try that definitely, I just don't want the thing ripping off downhill at 40+.

Scott Alexander

I've always had those problems with my old 2009 zipp 808 (which I still race on), so I actually carve that hole out a little bigger until it doesn't rub anywhere. The cover will use the rotational (centrifugal, or is it centripetal?) force kept in place by the screws/anchors with the spokes.

Josh Church

@Scott Alexander Thanks for the advice. I am still working on it. I just talked to owner on the phone today, he wants me to shave an little off the outer diameter see if that works better and if so, he is going to make a new one with those measurements

Gordon Cherwoniak

@Josh Church Sorry late to this thread.  Not sure this will help but I always tape mine on the inside to pull it as tight as possible to the spokes on the cassette side.

Wheelbuilder suggests at least 5mm clearance between largest cog and spokes. 

Josh Church

@Gordon Cherwoniak never too late for good advice. Thanks a lot.