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Thread: DIY front splitter materials

  1. #1
    Registered User spiller's Avatar
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    DIY front splitter materials

    I been looking into basic front splitters mainly because im bored, but also to promote improved radiator efficiency and front end aero (when my car actually runs one day). There are a few universal carbon fibre/FRP type kits that you can buy from overseas but shipping is a killer and essentially you still have to cut and measure (basically make the fucking thing anyway). I dont need flashy CF as its probably going to get smashed anyway so I figured id look into making one myself.

    Just looking at a simple flat bottom design and probably extending forwards of the front bumper by 50-70mm. pretty basic. Google reveals some dodgy shit that probably wouldnt make it out of the pits without falling off, but others have used plywood or alloy. Obviously needs to be something that's fairly light weight, but rigid (surely alloy is going to flap around all over the place at high speeds). I was thinking along the lines of polyethylene (the same stuff plastic chopping boards are made of) but NFI where to get it in large quantities in Australia (or anywhere) and its probably expensive as fuck. Plywood is cheap and easy but a bit too backyarder for my liking.

    anyone done this? (note i have no glassing skills so making a mold and building one that way is not an option for me).

  2. #2
    Registered User stb's Avatar
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    I think PE would be too flexy - or heavy if it is thick enough to not be. Alloy is much more rigid per unit thickness. I've seen plywood and fibreglass used, plywood is easy to replace if damaged... and can be painted or stained!

  3. #3
    This space left blank Ben Wilson's Avatar
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    Ply has to be the go, paint it black and if anyone asks tell them it's unidirectional carbon.
    Imagination is more important than knowledge.

  4. #4
    Brobdingnagian Member Mighty Mouse's Avatar
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    balsa(or thin ply if you dont mind more weight) covered in glass would be the go if you needed to shape it.
    Aluminium if its just straight.

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    Real life axe man Justin Bieber's Avatar
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    If you're that worried about how it looks, throw on a layer of fibreglass over the top of it?
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    Registered User Farrell's Avatar
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    On my clubman, the splitter is made from 5mm ply.

    Very cheap to make, and not overly heavy.

  7. #7
    Registered User spiller's Avatar
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    how hard would it be to put a layer of glass over the top? i know nothing about glass, do you use big sheets?

    farrell have you got any pics of yours?

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    You could make it out of polyurethane foam (coolroom insulation, comes in varying thicknesses) glue and pin it together, radius all the edges and cover in a layer or two of woven rovings glass with epoxy resin. You can cut the foam with a serrated knife and you don't need too much more in the way of tools to work with the glass and epoxy.

    Mick

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    faarken doublepost.

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    Registered User scooby36's Avatar
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    12mm 5 ply from bunnings on my silvia, more rigid than the 9mm 3ply that i used on version 1.

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  11. #11
    Registered User spiller's Avatar
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    Jmick, thanks for the suggestion, will look into the foam.

    scooby, that looks decent and very functional. How much does it weigh?

    Balsa wood would be good as it weighs fuck all but i think it'd be too weak for the purpose.

  12. #12
    Gas Turbine enthusiast da9jeff's Avatar
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    you wouldnt use balsa alone, youd laminate with glass or carbon. its just the shaping media really.
    Last edited by da9jeff; 07-01-12 at 04:35 PM.

  13. #13
    Registered User Farrell's Avatar
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    Here is the splitter on the clubby, it extends about 30mm out the front..


  14. #14
    Registered User spiller's Avatar
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    thanks for the detailed pic

    i notice a lot of the clubman type cars have tiny splitters, why is that?

  15. #15
    Meh
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    Quote Originally Posted by spiller View Post
    thanks for the detailed pic

    i notice a lot of the clubman type cars have tiny splitters, why is that?
    The old rules used to limit the length of the front bodywork to 600 mm in front of the front axle, it's now 1,000 mm. So the older cars have shorter noses.

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    Mine is ply also(8mm) and it goes 100mm in front of bar way back to the firewall. No flexi problems if fitted correctly.

  17. #17
    Registered User Farrell's Avatar
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    Sorry for the lack of detail




  18. #18
    Registered User Streety's Avatar
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    There is a really good blog that shows one of the guys making a carbon fibre splitter from scratch. That said the same guy will make the next one from ply wood due to only being a few kilo's heavier and much cheaper

    http://www.michaelhiscoe.com/2011/09...ecar-splitter/

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    Registered User Momus's Avatar
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    Quote Originally Posted by spiller View Post
    how hard would it be to put a layer of glass over the top? i know nothing about glass, do you use big sheets?

    farrell have you got any pics of yours?
    Easy to do and fibreglass is the way to attach any features, brackets, reinforcement etc.
    A Bunnings $39.00 bucket kit gives you a sq. mtr or so of medium mat and resin. It will be rough side out- ie not at all smooth though.

  20. #20
    Registered User lightyear's Avatar
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    Use the stuff i use.... The alloy skined plastic they use for sign writing. Can't remember the name. But it is very stiff, and light enough. You can bend it, as long as you don't go doing a sharp 90 deg bend.
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    Quote Originally Posted by lightyear View Post
    Use the stuff i use.... The alloy skined plastic they use for sign writing. Can't remember the name..........

    It's called Alubond from memory.

    Mick

  22. #22
    Hungry Hungry Hippo Tripper's Avatar
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    what about using corflute instead of balsa and covering with glass
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  23. #23
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    Quote Originally Posted by tripper View Post
    what about using corflute instead of balsa and covering with glass
    The glass won't adhere real well to the corflute, even with epoxy resin so less strength and possible delamination down the track. (no pun intended)

    Mick

  24. #24
    Bannered takai's Avatar
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    I made mine with 3mm ply, laminated with a thin sheet of fibreglass, and had a bit of 15x25 alu angle screwed to the upper side of it for rigidity.
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  25. #25
    Hungry Hungry Hippo Tripper's Avatar
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    Quote Originally Posted by JMick View Post
    The glass won't adhere real well to the corflute, even with epoxy resin so less strength and possible delamination down the track. (no pun intended)

    Mick
    fair enough was just a thought. the only other cheap option i can think of is stealing a big street sign, hilux type ute with a ladder and high vis clothing works wonders
    you cant spell advertisements without semen between the tits

  26. #26
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    Quote Originally Posted by tripper View Post
    fair enough was just a thought. the only other cheap option i can think of is stealing a big street sign, hilux type ute with a ladder and high vis clothing works wonders
    This, real estate signs.

  27. #27
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    Quote Originally Posted by tripper View Post
    fair enough was just a thought. the only other cheap option i can think of is stealing a big street sign, hilux type ute with a ladder and high vis clothing works wonders
    This, real estate signs.

  28. #28
    Peoples Champ Fatboy's Avatar
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    Thanks for the input fuckhead...

    P.S - See ya. Say hi to your Mum for me...
    Last edited by Fatboy; 07-01-12 at 09:26 PM.
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  29. #29
    muzzytt Mazda_DohC's Avatar
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    Quote Originally Posted by Streety View Post
    There is a really good blog that shows one of the guys making a carbon fibre splitter from scratch. That said the same guy will make the next one from ply wood due to only being a few kilo's heavier and much cheaper

    http://www.michaelhiscoe.com/2011/09...ecar-splitter/
    what a small world .. I know that car its up in the central coast . the blokes a real racer and has a nicely set up car. the carbon fiber kit he got i delivered to him as I work for an interntional couirer company.
    97 vvti supra

  30. #30
    muzzytt Mazda_DohC's Avatar
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    Quote Originally Posted by Streety View Post
    There is a really good blog that shows one of the guys making a carbon fibre splitter from scratch. That said the same guy will make the next one from ply wood due to only being a few kilo's heavier and much cheaper

    http://www.michaelhiscoe.com/2011/09...ecar-splitter/
    what a small world .. I know that car its up in the central coast . the blokes a real racer and has a nicely set up car. the carbon fibre kit he got i delivered to him as I work for an interntional couirer company.
    97 vvti supra

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