(continued from above)
Using a plumb bob to trace the bumper cover outline, Ryan and Ed marked the splitter's main plane a full 5" beyond the front bumper cover's shape, per the PPIHC rules, and used massive 3/4" thick slab of plywood. I had voted for 3/8" or maybe 1/2" thick material, but JasonM wanted to make it Brianne Proof (TM), so he went Texas
Once the aluminum structure was added to the splitter, it became even more rigid and was ready for some paint. In case you are wondering, the entire thing weighed 38 pounds and if 1/2" thick material was used it would have been closer to 25 pounds. The splitter sits about 4" lower than the wrapped exhaust header and oil pan, with about 3" of front ground clearance. The main plane was painted with gloss black enamel and the aluminum was shot with some black spray enamel by Brianne herself. After the splitter dried overnight it was bolted on (via the four front brackets and two rear bolts into weld nuts added to the lower subframe), we had a big air gap to fill between the bumper cover and the splitter main plane.
We don't have many pictures showing the air dam construction, as they are still on the memory card in my Nikon, which is in Colorado. I will show it's construction in my post after Pikes Peak. The air dam is simple and functional. JasonM had picked up a 7' length roll of 3/16" thick ABS plastic sheeting from a local circle track supplier (Smiley's), which was a red that matched the wrap. I made a dozen or so brackets from 2" x 2" x 1/8" angle aluminum, bolted them to the splitter, with a drilled hole and a Rivet Nut (RivNut) pressed into place on each vertical portion - with the help of two of Brianne's volunteer Austin crew members. This series of lower brackets (see below, right) allowed us to bolt the lower edge of the ABS sheeting onto the brackets for easy removal of the splitter. The upper section was riveted onto the bumper cover with backing washers behind. This looks a little crude, but it keeps the high pressure air pressing against the splitter, directs some over the hood, and forces some of the air stream into the radiator or intercooler openings in the bumper cover. Two slots for brake ducts can be seen at the bottom edges.
In order to make sure we were on the right path, we did some "static testing" during construction. Ed stood on the plywood splitter without any aluminum structure in place... and it barely flexed at all. I was about to choke when he hopped up on the lip! Once it was beefed up with a few pounds of aluminum tubing, Brianne was hopping up on the thing like a kid on a trampoline. It doesn't flex an 1/8" with her on the thing, so I guess it's Brianne Proof after all.
Brianne was a good sport and posed for a couple of splitter pictures, above. You can see the finished air dam on the right picture, and the splitter structure is visible in the left picture. There is a front tow strap we added visible in the center, poking out of a slot between the splitter and air dam. This air damn was made very quickly and only completed an hour before they loaded the car into the trailer to head out.
More pictures above are of the completed car, right before it went into the Vorshlag trailer Sunday afternoon.
Cool desktop wallpaper, with a ghosted view from the hood open merged with a picture of the hood closed: http://vorshlag.smugmug.com/Vorshlag...428-copy-O.jpg