Carbon Fiber Cycling Shoes
Long time no see! Introducing some homemade cycling shoes!
I’ve always wanted to use carbon fiber to make something. It’s a pretty cool material and was less boring sounding than wood working and less costly than metal working. Find practical applications was actually more difficult than I thought. With my current cycling shoes wearing thin, I figure carbon fiber could reinforce a pair of soccer cleats making it a cycling shoe!
Carbon fiber can be used and processed in many ways. Because I had limited access to equipment and don’t have a bunch of fun money, I took some shortcuts and trade offs to make the carbon fiber cycling shoes work.
The plan is to use a donor shoe as the upper, add carbon fiber to make the sole stiffer and add bolts for cleat attachment. I have only found one forum post where someone else attempted this so prior information was sparse. Found some cheap orange cleats on ebay so next was getting the carbon fiber materials.
Carbon fiber itself is a flexible cloth which is great to warp around things. Like cloth there are different weaves. I picked a 2x2 twill carbon fiber weave because it was more flexible for tight bends. To cure the carbon fiber, I used Max 1618 epoxy which did not require high heat curing temperatures.
Because I didn’t have an oven in which I can cure the carbon fiber nor did I want to invest in a vacuum pump, I opted to just let my carbon fiber cure in the garage while being tightly wrapped in saran warp. The trade offs from not using an oven is that the epoxy may not cure as hard or impregnate the epoxy as well. The trade offs for not using a vacuum pump is that the part may end up being heavier as excess epoxy will remain in the part.
I did research pre-preg carbon fiber which was essentially carbon fiber with epoxy already in it. While this was nice, pre-preg was quite expensive and also had a shelf life. Perhaps if I really knew what I was going to make with carbon fiber than I would opt for pre-preg carbon fiber down the line.
Regarding wrapping the shoe in saran wrap, I also used a layer of peel ply between the saran wrap and carbon. This allowed me to easily remove the saran wrap since it would not be in contact with the epoxy. The peel ply doesn’t stick to epoxy so that was easy to remove too.
I used a Nike Mercurial as a donor shoe primarily because it looked cool. To create a smooth bottom, I removed the studs from the bottom of the shoe with a dremel and sanded down the surface. I kept the rear studs so they balance with a cleat on.
To prove that this concept will even work, I measured out 3 holes for cleats with my current pair of cycling shoes. To receive the screws from the cleat bolts, I bought a Shimano cleat nut replacement part SH-R121 which is normally for a Shimano shoe. This part is amazing because it had the correct 3 screw spacing and curvature already set in one piece of thin metal! I took a test ride in the the proof of concept and they functioned! They felt a but sloppy because the bottom of the shoe was way to flexible but they did clip in and out on command :)
Carbon fiber could be added in a couple ways to the shoe.
I originally wanted to remove the sole of the shoe and cover that completely with carbon fiber. Unfortunately, I couldn’t get the sole off the shoe. I even tried several methods including boiling water but it wasn’t budging.
Another method was to create a carbon fiber insert inside the shoe. The great thing would be that the insole may be transferable and I wouldn’t damage the outside of the shoe. I needed to get a mold of the inside of the shoe with a material that also would durable and not be brittle. I came across epoxy clay which is amazing! I was able to model the inside of the shoe. The biggest issue I realized afterwards was that an insert, even replacing the original insole, would have taken up too much space inside the shoe. As a result, I never made the carbon fiber insert.
The most obvious method is to epoxy carbon fiber on to the bottom of the shoe. I prepared a template for the carbon fiber cutout but taping masking tape on the shoe and removing it. This way, the masking tape perseveres the 3D aspect of the shape. I cut out three pieces of carbon fiber of the same shape which turned out harder than expected. Intricate parts of the template were hard to create because the carbon fiber just fell apart when there wasn’t enough material to hold it together. Sharper scissors or using pre-preg carbon would have helped.
I prepped the shoe with masking tape to protect the upper and started epoxying the carbon fiber to the shoe. Overall it was an easy process. I wrapped the shoe in peel-ply and saran wrap and then let it sit outside for a day.
The results were pretty good! I did notice some areas where the carbon was more bare. I think my distribution of epoxy wasn’t too even as I tried not to add too much epoxy. It felt pretty stiff even with 3 layers of carbon fiber. What surprised me was how sharp the carbon fiber became after the epoxy. I was pricked so many times that I wonder if it was a safety hazard. Carbon fiber splinters are probably not good. I sanded down the shoe and tried to remove as much masking tape as I could. Looking back, I probably didn’t need the masking tape anyways. I drilled the 3 holes again for the cleat and added some skateboarding tape for grip and we were off to try it out!
I bravely took the shoe out for a shop ride on Sunday as the first ride. It was 50 miles but I also took my regular right shoe as backup. The new shoe clipped in and out easily and even made the nice snapping noise. It felt stable and secure even during the climbs. From a functionality point of view, they worked. From a comfort point of view it left a bit to be desired.
Here were some of the comfort problems. Because I used a soccer shoe, the toe box was smaller than most shoes; I guess it would be beneficial for a soccer player. This wasn’t great for cycling as it felt a little too snug after my foot warmed up. The Shimano cleat I used ever so slightly elevated the area around the ball of my foot but I didn’t offset that with something at the heel of my foot. This cause a hot spot problem which actually led me to swap back to my regular shoe. The last problem was a comfort and usability problem. Soccer cleats don’t have the best lateral stiffness so unclipping took more force than I would like. It wasn’t difficult; when the heel moved out-bound, it would unclip the shoe a little bit later than usual. As a result, it didn’t feel very ergonomic and was a little annoying.
Well, the shoe worked. Though not super well. I think using a soccer cleat as a donor shoe because it looked cool helped spark conversations but wasn’t the best donor shoe. I probably will not make the left pair with the soccer shoes and may find a new donor shoe. To be honest, my current cycling shoes are going to hit the bin soon so I might just go and purchase a new pair of cycling shoes.
Overall this was a very fun project. I was glad I got into carbon fiber and now have the materials on the ready for new projects. Maybe next time i will have something more permanent to share :)