DIY chain stay protectors ALU foil tape, a step-by-step
 

Some folks expressed interest when I mentioned that I stooped to making my own "homebrew" substitute chain stay protecteors, to fill the void left since nobody sells the Classic/Vintage thick stainless steel PSA jobs we recall from BITD.
I have a step-by-step with this thread so you can make your own from adhesive aluminum foil tape (know as HVAC tape in the trade) just as I do.
These are so simple a child can do it, as long as such a child can handle an Xacto style knife and scissors.
The tape produces a reasonable facsimile to the original SS items, and you have the advantage of making them larger or smaller to best fit YOUR chainstays...BUT the material is not as shiny or as durable!
For more durability I have double-layered these but even then it's a much softer and thinner metal, no way around that fact.

Let's start: I have a few rolls of HVAC tape, I find it varies slightly in thickness so if you have a choice go for some that's 4-mil rather than 3.4 to 3.6-mil.
I see that there's a "Reinforced HVAC" tape with fiberglass strands embedded, I have not used any but it MIGHT be a more durable material.
The stuff I have is (nominally) 2" wide with a peel-off carrier backing paper and strong Pressure Sensitive Adhesive (PSA) under that backing.

https://cimg4.ibsrv.net/gimg/bikefor...08ee1e8ac6.jpg
for this demo I used a Stay Tuff plastic item for my template, below is a roll of the 2" 4-mil HVAC tape
https://cimg8.ibsrv.net/gimg/bikefor...979eaf7e6c.jpg
taped to a cutting board, Stay Tuff aligned with one edge, you can get 2 out of one 2" wide piece, so why not?
https://cimg4.ibsrv.net/gimg/bikefor...a0f5259437.jpg
one traced with a Sharpie, the ink wipes off later with any alcohol
https://cimg8.ibsrv.net/gimg/bikefor...5f1095e05e.jpg
second traced.
https://cimg2.ibsrv.net/gimg/bikefor...7f931b2fc0.jpg
both cut with ruler/straight edge and Xacto knife, but rounded ends not yet cut...
https://cimg1.ibsrv.net/gimg/bikefor...0b4cdda117.jpg
...cause I cut the curves with scissors, easier to control
https://cimg6.ibsrv.net/gimg/bikefor...99dfa64db5.jpg
Here's the chain stay on a Univega for this demo, it's cleaned with alcohol but paint is chipped so final result will not be ideally smooth
https://cimg2.ibsrv.net/gimg/bikefor...f790aeaa15.jpg
backing paper peeled off and lined up on the stay, only the center of the tape is stuck down at first. I smooth that strip with any smooth plastic tool at hand, ideal tool is a "bone folder" but for this I used a paint brush handle
https://cimg6.ibsrv.net/gimg/bikefor...bd1b8a06b9.jpg
then work the rest of the tape down I do the top edge from center outward, then the bottom edge, to minimize getting wrinkles; smooth and "burnish" with the tool
https://cimg2.ibsrv.net/gimg/bikefor...fb65dc0bdd.jpg
final results: it's not as smooth as stainless since any irregularity under the tape will show, but...da ya go!

Good job!

I've often wondered (and I am a complete biking novice) if applying a thin layer of rubber cement in that location would work as well.

Would/could it? I'm no weight weenie.

Dunno but it sure might attract road dirt or other flotsam & jetsam ?!?

Still a few around.

​​​​​​https://defietsenmaker.nl/product/ca...num-one-piece/

​​​​​​https://defietsenmaker.nl/product/ch...m-the-mid-80s/

I bought one from him via eBay a couple of years back. It's an excellent product.

I need such a nice chainstay protector, but with the letters

Y o u r B I k e S u c k s


and since I'm not as fast as I used to be, make that one for the left chainstay, too. :thumb: :lol:

Thanks for finding them, of these 2 the bottom link goes to NOS Minoura items that are genuine stainless steel, the top link is for aluminum new products, which I believe are made in China and have seen them with several brands/logos but never bought any cause: aluminum.
I already have that (albeit much thinner) ;)
I also sincerely doubt that Campagnolo gave a license for use of their brand on these, but it's not any of my business. I should add I have no proof just my suspicion cause I found many similar examples years back from Chinese vendors (AliExpess and such) that were identical aside from the different embossed brands/logos
My only caveat re: the Minouras would be if the PSA is still good after nearly 40 years storage, but if it's dried out there are many double-stick tapes and films available to fix that.
Thanks again.

one more pic:

https://cimg9.ibsrv.net/gimg/bikefor...8dc7ce3a32.jpg
another recent example with a cleaner chain stay that came out a little smoother

In case you did not know, what you have there is the REAL DEAL. It's The one, The only, the BEST, The original,...DUCT Tape.

Etymology (& purity of language) alert: It's not "duct tape" but "duck tape" properly. Any HVAC contractor who knows anything at all wouldn't use "duck tape" for ducts, though I imagine that's how the usage was corrupted.

EDIT: to stay on topic, please note that stainless steel tape (4 mil) is indeed a thing -- https://www.mcmaster.com/tape/stainl...eel-foil-tape/
About a buck-fifty a foot for 1" wide. Stainless is of course a lot harder than aluminum, so I don't know how "cuttable" it is.

Well, it's one of those cases where you're both likely correct. According to the Oxford English Dictionary:

https://cimg9.ibsrv.net/gimg/bikefor...faa6bb8805.png

well I don't know how I missed that cause I am trolling the McMaster site often, but I will have to take the plunge and try some SS tape.
ANYthing can be cut with the proper blade, IMO.
;)

We used to call it 100 mile an hour tape because it was so sticky . I recently bought some from a refrigeration guy to use when I replaced the cooling unit on my refrigerator for my motor home . It is what is used on ducting not the cloth type tape. I had some ducting put in at my shop for my dust collector (grind shop) and they used the aluminum type not the cloth stuff.

You can milk anything with nipples.


https://cimg1.ibsrv.net/gimg/bikefor...47682ed9d0.png

I made a chainstay protector with fiberglas reinforced HVAC tape some years ago. It works great, but it isn't pretty - you can see the netting.

Got a pic of this?

I sold that bike some time ago, but here is a photo of the type of tape used.

https://cimg1.ibsrv.net/gimg/bikefor...883ff6bb15.jpg

That's a great idea.. Thanks for sharing/posting.. :thumb:
On my Univega, the PO wrapped some ugly black electrical tape that is an eyesore but now I have an alternative to try.. Thanks..

That HVAC tape might actually look "right" on the right kind of rough & ready frame, like a Diamond Back Overdrive Comp, et al.