Castelli Free Aero Race 4.0 Bib Shorts Review

The new Castelli Free Aero Race 4.0 bib shorts were developed for and with the riders of Team Ineos (formerly Team Sky). It’s a high-performance model, but also very comfortable for sporty or “committed” use.

By Guillaume Judas – Photos: 3bikes.fr

Working with the most prolific team of recent years on Grand Tours, known for its theory of marginal gains, implies frequent re-evaluation. But Castelli is also not new to the cycling world, as it was the scorpion brand that introduced the first Lycra bib shorts in the early 80s, or more recently the famous Gabba jackets, copied – but rarely equaled – by all competitors for several years. Castelli, therefore, means frequent innovations, put at the service of professional teams, but also of riders whose main concern is performance.

Among the characteristics useful for performance are aerodynamics, lightness, breathability, insulation, and comfort, to varying degrees depending on the garment’s objective. For these new Free Aero Race 4.0 bib shorts, which are the fourth version as the name indicates (the first model of the name was released in 2007), the idea is nothing less than to make them the race bib shorts for all courses, for professionals. This speaks to their level of development, even if there are, in absolute terms, lighter, more airy, and undoubtedly more padded chamois pads. But be careful, because comfort is not only judged by the softness of the saddle or the chamois pad. The placement of the latter, its seams, and its ability to prevent chafing, which can lead to injuries in the long run, are also fundamental for providing comfort when pedaling dynamically (and not just by coasting on false flats).

As for the aerodynamic aspect touted by the brand, even if it is impossible for us to verify it on the field with our measurement tools, we already know that it is predominant when it comes to clothing. The bib shorts are therefore made from a fabric with a dimpled surface, known for controlling airflow.

A new construction

To develop these new bib shorts, each part was carefully considered. New materials, new type of construction, new chamois pad, in order to improve comfort by first optimizing the fit to offer as much freedom of movement as possible, while remaining aerodynamic, of course. Twelve panels are therefore used for the manufacture of these bib shorts to ensure their support without any feeling of misplaced compression.

The leg endings are laser-cut with a softer, more stretchy material. Inside, vertical silicone strips do not limit the stretch of the hems for a better fit while improving the perceived comfort along the thighs.

The straps and back are distinguished by their minimalist side, with a luxurious-looking, breathable, and lightweight material, designed to be completely forgotten in hot weather. A small pocket on the back is noticeable for storing a radio, to meet the needs of professional cyclists.

The new Progetto X2 Air Seamless insert is above all the element on which you will focus your attention to evaluate the comfort of the bib shorts. Compared to the already excellent Progetto pad, it is softer to the touch and more stretchable, with three layers.

Under the top layer of the insert, there is padding of varying thickness depending on the location, and finally a kind of perforated viscous pad that moves independently of the outer layer.

Under the top layer, there is padding of varying thickness depending on the location, and finally a kind of perforated viscous pad that moves independently of the outer layer. This ensures excellent adaptation to all buttock and saddle shapes, as well as to all pedaling styles.

On the road

The fit is immediately excellent, even though you only have to choose from six sizes. When you think about it, six sizes to adapt to all body types while maintaining comfort and aerodynamic qualities is relatively few. But here, we notice that the bib shorts are just a tad long for our taste on the thighs, but that’s the current trend. And it’s also the assurance, we are told, of ever better aerodynamics (sic). Furthermore, we feel a slight compressive effect on the thighs and glutes, but we don’t feel constricted. All panels are adjusted to the contours of the body, without the slightest crease. The fabrics are elastic enough for the bib shorts to follow pedaling movements. Even when standing (which is not normally the ideal position for bib shorts), the straps do not pull on the torso. They are thin and light, and simply hold the garment in place. Once the correct position of the leg endings is found (I don’t like, for example, feeling a tightening effect on the protrusion of my quadriceps during effort), we notice that the leg endings with the vertical silicone strips do not move at all. And they do not cause any irritation in use.

As for the insert, or chamois pad, even if with synthetic linings we are far from the ancient real chamois leather, its comfort is of a very high level, at least for rides up to 5 hours and in very hot weather. Not used to longer rides, we did not attempt an “ultra” ride to test the bib shorts, but experience shows us that with heat and perspiration, it sometimes takes much less to suffer from the saddle. In our opinion, there is enough padding where we need it most, but above all the top layer is very comfortable against the skin. Some are used to thicker inserts, especially on the back. But in reality, we immediately appreciate on hot days the feeling of wearing a lighter garment.

Nothing to say in terms of finish, except perhaps regarding the glued logos behind the thighs. They peel off after several washes and eventually disappear. Just a shame, but without any consequence on the durability of the garment.

A word about the jersey

As you may have noticed in some photos, our 3bikes.fr jerseys are also manufactured by Castelli, through the brand’s customization service, as here. Our choice fell on the Free Aero Race 6.0 Jersey FZ, which happens to be the model that combines perfectly with the Free Aero Race 4.0 bib shorts. It is an aerodynamic jersey, but also very light and very comfortable, as our ambassadors have noted.

The cut is also close to the body, but without the jersey giving the impression of compressing or restricting movement. The pockets are spacious, but filling them does not alter the fit of the jersey.

And finally, rides in moderate heat (around 30°C) did not even require a full opening of the jersey for ventilation. In short, like the bib shorts it complements, this very high-end jersey is distinguished by its ability to be forgotten, both during intense effort and during long, more relaxed rides. And finally, let’s also note that both the bib shorts and the jersey have high prices, but not entirely excessive either. At €169.95, the Free Aero Race 4.0 bib shorts even seem to us to be the best value for money in the high-end sector.

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