This weekend I made some shock-socks, the idea being to protect the shock shaft from stones and grit which can damage the shock shaft; when the shock shaft is damaged the shock seals will wear and leak.
I started with a Waterproof coat from the local market, 4 EUR!. It's made by Tribord, which is a Decathalon brand, it's something like this.
https://www.decathlon.es/es/p/chaqueta-impermeable-de-montana-y-trekking-quechua-nh100-de-hombre/_/R-p-5332?mc=8300325&c=AZULhttps://www.decathlon.es/es/p/chaqueta-impermeable-de-montana-y-trekking-quechua-nh100-de-hombre/_/R-p-5332?mc=8300325&c=AZULIf you can get similar waterproof material go for it.
You need an XXXL (EUR) size / XXL (USA), see photo. Just make sure you've got enough material to fit the template.
You'll need 2M of 2cm wide velcro strip and about 1.5M of 1cm wide elastic. Bra-strap elastic seems to have the right amount of stretch.
Next, cut the arms off the coat. As you need as much of the arm material as possible unpick the seams on the arms and unfold the material where it's joined.
Make a template out of paper, I used a reasonably thick large sheet.
Rear shocks are 60x36cm, front is 49x36cm. If you make the template as-per my photo you only need one sheet, make the rears first, then cut or fold the template and use it for the front shocks.
The 36cm width is a snug fit and the 60cm (rear)/49cm (front) length is perfect, but if you want a looser fit or more material for the fold-overs then increase the 'shock area' or fold dimensions accordingly.
Pin the template to arm of the coat, cut around the template for the REAR shock. Repeat on the other arm for the second rear shock.
The rear shocks need cut-outs at the bottom to accommodate the plastic shock guard supports that are fixed to the bottom of the shocks (see photo for fitting details).
Both front and rear shocks have the reservoir/piggy-back so there is a cutout at the top corners for these too.
Pin the template to the back of the coat, place the template making sure that you can cut out two of them. Cut out for one FRONT shock, repeat for the second front shock.
You should now have 4 pieces of material for 4 shocks.
Next, make the diagonal cuts on the fold lines so that the material can be folded over. 2 cuts for the front shocks, 6 cuts for the rear shocks.
Next, fold over the 0.5cm of the all of the edges of the material towards the INSIDE and sew, I used a vintage sewing machine for the task. Make sure the thread you're using is strong. A 100% polyester thread is ideal. You can pin the material over if it helps, I did the first one using pins, but was lazy and did the rest without using pins. Make sure you don't fold over too much material or it won't fit round the shock.
If your sewing machine has a zig-zag pattern then use a 2-3mm zig-zag pattern over the cut-out folds and corners over the top of the first thread used to hold the corners in place, this just gives the corners extra strength and should protect them from tears.
Next, sew the furry (loop) side of the velcro to the OUTSIDE of the shock cover (as indicated). Sew along both sides and each end to create a rectangle.
Next, sew the sticky (hook) side of the velcro to the INSIDE of the shock cover (as indicated). Sew along both sides and each end to create a rectangle.
Finally, sew on elastic to the top and bottom of the each shock sock on the inside as indicated. The elastic must be stretched while it is sewed on so that when it is released it gathers the material. You also need a bit of extra elastic to hold on to when you're feeding it though the machine, so make sure you add about 2-3cm for this. So pin the strip of elastic, 2-3cm from the end of it to one side of the sock, then stretch the elastic so it is flat with the material and pin the other side of it, then cut the elastic 2-3cm away from the pin. Then hold both ends of the elastic and feed it through the sewing machine. Stitch the elastic to the shock sock in a rectangle (i.e. along both sides and a 3-4 stiches at each end to form a rectangle.
Done!
To actually fit them start at the bottom, fold the shock sock over the shock about half way up the shock, with the velcro facing towards the reservoir, connect about 5-10cm of velcro and pull the sock cover down over the bottom of the spring so the elastic is below it. then connect about 5-10cm of velcro at the top and pull it over the reservoir/piggy-back so the elastic is above the reservoir. Then connect the rest of the velcro along the length of the shock, if you stick a finger in and run it from near the top towards the bottom it's easy to get good velcro alignment.
They're pretty each to make, but a bit time consuming. It took me two evenings to design and make them, and I'm no expert at making things either.
See attached photos!
Please note that the design is copyright 2020 Dominic Clifton (C), if you want to use it commercially please contact me.
If anyone wants to make printable DXF files for the template please do and post them here!
Likewise, if you make up some socks please post your pictures, I'd love to see them.
Enjoy!