2G Rear Diffuser Design

[Redshark]

I'll hope that you can also provide shipping to Europe, i really want one by the looks of it

 

[gofer]

Looks great!

How are the DSM's running a rear chromoly subframe going to run this diffuser Atuca?

 

[Atuca]

Maybe I'll have to have you just give me a subframe to "test" with so I can figure out how to do it

I still havn't gotten around to planning a subframe panel for the GST, let alone Paul's. GST subframe guys may need me to get a panel made for them, but you Paul subframe guys I'm sure could figure something out

First production piece pulled from the mold will be this weekend; I'm pretty excited!

 

[AngelOfPassion]

These are going to be really cool. I have a feeling it is too late to switch my selection to carbon fiber HAHA.

 

[Atuca]

Haha, lets see what a pulled fiberglass version looks like. Once I have a production subframe panel done, I'll mount it on my car and take new measurements for the diffuser panel itself. Based on the time the mold took for the subframe panel, I'm guessing a week for the diffuser panel mold, and 4 days for the actual piece.

Since the mold is done for the subframe though we can continue to make the subframe panels while making the diffuser panels, so things will speed up. There's been a lot of trial and error, failed mold attempts, and just being busy in general. However I been documenting everything so I know the amounts to use for each product (gel coat/ resin/thinner/hardener/ect) on what layer. So things are definitely getting exciting!

I wanted to try and get Beau's done before his track day, but at the same time I don't want to rush things after all the time that went into the design!

I'm headed out now to do another fiberglass layer on the first subframe panel. Stay tuned

 

[Atuca]

Sorry for not posting an update Angel (I forget you aren't on my facebook sometimes) but for you and the rest, I bought a new house and it was not an easy process, taking up much of my time. I've been moved in for about 2 weeks now and spent the last two weekends cleaning up, moving in, and getting new furniture (i.e. shopping).

We have one subframe panel just about done (we had to scrap one due to mistakes) and I expect to get back to finishing everything shortly.

 

[AngelOfPassion]

It's all good bro, I check in here from time to time to see if anything has been posted up.

Thanks for the update.

 

[Atuca]

So Wednesday I went back to work on the diffuser at the friend's house I started it in. Funny story: The weekend after I moved out, the landlord came and took the mustang out.. After all that time with it being in the way, it came out after I was.

Anyways, my friend had been busy (in more ways then one.. his wife is pregnant! ) but we were able to get together and reorganize the garage after the mess I left it in moving out and after the car came out. We got everything resituated and got back to work on everything. I think I've said this before, but this weekend we should be pulling out first production piece.

To the testers, I am going to be cutting drilling ect and installing this first one on my car to make sure everything fits like it is suppose to, and that our mold is going to be good for pulling more. I think AngelofPassion, you wanted one already cut and pre drilled for you anyways? I wouldn't be doing this for any others, but if you wanted to save a few weeks of waiting this first one may be good for you.

The strakes still need to be sourced.. I never got around to going to the fabricator's shop.. Once the subframe panel is done we can shape the diffuser panel for final time.

I didn't take any pictures yesterday, but I'll be sure to grab some of the first piece getting pulled Saturday!

 

[KeelesKustome]

8/15/2013

Just keeping a date diary when I check in.

 

[Atuca]

Wednesday this should be getting pulled.

Have emails out to two potential strake producers. One is a one man show, the other is a large facility who wants to do it on 4' x 8' sheets at a time, so I have to get the strakes laid out on a CAD file for them, and I have an email out to someone to do that for me since I don't have the ability to output the file format they want at the shop.

Friend had a loss in the family and put a few days of delay on everything, however he has been diligent in making time to finish this. He has sent me pictures and says everything is good to go by Wednesday.

 

[AngelOfPassion]

To the testers, I am going to be cutting drilling ect and installing this first one on my car to make sure everything fits like it is suppose to, and that our mold is going to be good for pulling more. I think AngelofPassion, you wanted one already cut and pre drilled for you anyways? I wouldn't be doing this for any others, but if you wanted to save a few weeks of waiting this first one may be good for you.

If that first one comes out OK I wouldn't mind taking it. Pre cut and pre drilled is going to make my life A LOT easier. I'm not nearly as resourceful as you guys when it comes to this stuff...

Really excited to start seeing this thing in action and installed onto one of our vehicles!

Btw, sorry for your friends loss... wish him well for us.

 

[Atuca]

It was pulled, now awaiting some time to get it installed on my car, probably this weekend.

We learned a lot from this first piece, thickness and amount of layers, amounts of resin and hardener, and feeling much more confident about future pieces. My friend had already begun work on the second; I stopped by while he was spraying the pva.

Lets hope after all this time it installs as designed!

It sure feels good to hold a piece I've had developed in my head for months, in real life. It's lightweight and I expect everything to go smoothly. Just gotta sand this one down, drill the holes, and paint it up. Can't wait!!

 

[Planckscale]

Any update bro!

 

[Atuca]

Nothing until next week; my friend spent a week in Tahoe and I am having a house warming party this weekend. Just a bad overlap in schedules, but I'll post soon as it's on my car.

 

[Atuca]

Got the email finally on strakes! They can fit 42 strakes on a 48 x 120 sheet of aluminum. Making me buy the whole sheet but I think it's my only option. No clue on eta for them to finish but this was one of the last steps! This is going to be a good week! First this and next WTAC results/pictures!!

 

[my dreamt dsm]

Why can't it be along the lines of something like this? Easier to make? I don't know I'm no pro so I'm asking
Or similar to the Voltex diffuser to the evolutions. Don't mind my paint skills

 

[Atuca]

Function was the goal of the project; the first 3 to 4 pages we discuss angle requirements to be functional, and the issues with the spare tire getting in the way and sub frame height. Review those pages and if you see something that I over looked, I am all ears. However I believe I have a design that works that will be relatively easy to install on a stock body DSM. Those who want function more extreme and have a hacksaw ready for their spare tire have an option as well with adjust-ability and that too has been discussed a few pages back.

 

[AngelOfPassion]

Strakes! Hell yeah.

 

[gofer]

I PS'd a Evo Voltex diffuser on my 2g a few years ago upon request, it would HAVE to be functional because it looks terrible with the body lines of a 2g.

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[Bud92gsx]

I made a sheet metal one for my front..But i think if you follow the lines of the 1g rear bumper it may actually create lift? What yall think

Ya corey that looks horrid bro.

 

[LandSpeed-DSM]

Why do you want lift, Bud?

 

[Bud92gsx]

Sorry..I meant following the 1g rear bumper the way i did the front would create lift.So maybe thats not such a good idea..

 

[Atuca]

Got an update from the shop today: strakes should be done (cut and formed) on the 29th. He also had me speak with the engineer next door to them and we changed the aluminum plans a bit. I was worried about stock routed exhausts melting the strakes while the car sat at idle. So after talking, we decided on 5052 .080 aluminum. It is a bit heavier by 2 pounds for a set (about 8oz more per strake) but I think it reduces the chances of failures in all cases. If all else fails, I can always custom order specific grade metals (alum or steel) and thickness for certain applications.

I was sick this last weekend but Thursday we reinforced the subframe panel with one more layer in critical areas we felt may need to be thicker in order to structurally support the weight difference after being cut to allow a stock exhaust setup. I still think people should just reroute their exhaust



Now it is reinforced, I am going to drill the holes to mount it and make sure everything works as planned. I think I may use some dowels (or maybe just a washer tbh) to keep the rear sway bar mounts and bushings from not pressing against the fiberglass panel. Once that is done, I will be painting this for pictures and prettiness. Lucky tester number 1

That's an update for this week, have a good one!

 

[AngelOfPassion]

Don't hate on us stock routed exhaust guys... we helped fund this!

Glad to hear the strakes are going to be done soon. Can't wait to see this thing.

 

[mitsumikey]

Ive been watching this thread patiently for a year now! I have high hopes, and if they are met plans to purchase!