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Old 11-22-2010, 10:00 PM   #1
68Cadillac
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Default Front Bumper Wind Splitter - DIY

Decided to make a splitter for the front of the wagon. Been jonesing to do this for a while.


Starting with design and template making in cheap materials.


Initial design effort


From the side


The proportions were off in a spot or two


Refine the design


Looks good now.

More to come as the build progresses.
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Old 11-22-2010, 10:10 PM   #2
jimbosv650
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WRB

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what are you going to make it out of?
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Old 11-22-2010, 11:05 PM   #3
wrx jay
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This looks promising.
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Old 11-22-2010, 11:11 PM   #4
nickrice20
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What material are you planning on using?
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Old 11-22-2010, 11:45 PM   #5
68Cadillac
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Default

I wanted a material that was inexpensive, took impacts like a champ, high rigidity, resistant to solvents/car fluids, resists wear, would bend and reform back into shape without cracking or warping.

Only one material I could find that fit that. High-density polyethylene (HDPE) 1/4 inch thickness. I already ordered it. In black.

Its the same material with which they make cutting boards.


*EDIT: DO not use HPDE for the sole material for a front splitter. It could be used as a facing sheet (1/16 inch thick) to take the scraps, bumps, and nicks of being a splitter. Riveted on bottom of a stiffer main splitter made from somthing else. But it is not rigid enough in 1/4 to work. It just flopped all around and got soft when heated up. BAD TIMES. Learn from my folly and don't use it for the sole material.

Last edited by 68Cadillac; 10-03-2012 at 12:20 AM. Reason: added image
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Old 11-23-2010, 01:06 AM   #6
eurospek
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Subscribed.
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Old 11-23-2010, 01:16 AM   #7
T WRX rawr
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interesting. Look cool, lets see some progress!
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Old 11-23-2010, 01:26 AM   #8
PlasticFoamMan
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buh bye WRX :(

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My buddy did this on his track beater and it turned out pretty well (with little mention to some ultra-ghetto cutting and measuring )

Your measurements will serve you well!
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Old 11-23-2010, 01:27 AM   #9
FlannelWagon
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may I suggest when you get the material, and cut out your splitter shape. taking a router and router a round edge to the front of the splitter.

just a thought, you might have already considered it.
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Old 11-23-2010, 02:19 AM   #10
68Cadillac
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Default

Quote:
Originally Posted by aspensti04 View Post
may I suggest when you get the material, and cut out your splitter shape. taking a router and router a round edge to the front of the splitter.

just a thought, you might have already considered it.
I have considered it. I thought about a 1/8 round for the top and beveling the bottom. I only have 1/4 inch to work with so I don't want to make it too thin. We'll have to see when I get to that portion.

Here's a cutaway cross section of what I'm thinking.

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Old 11-23-2010, 01:42 AM   #11
auzy07
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heck yea! I'll be keeping an eye on this thread! Depends how yours turns out, but this may be my spring project!
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Old 11-23-2010, 03:28 AM   #12
evan_impreza
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looks promising so far. nice work.
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Old 11-23-2010, 03:31 AM   #13
DoWork
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In for progress!
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Old 11-23-2010, 03:40 AM   #14
dantastic
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CGM STX #125

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Old 11-23-2010, 04:07 AM   #15
djerickd
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reminds me I need to make mine... I ordered ABS sheet from http://www.tapplastics.com/
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Old 11-23-2010, 05:28 AM   #16
jdmSpecC760
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Nice im going to make mine soon heres the DIY i found

http://www.s2ki.com/forums/index.php?showtopic=650262
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Old 11-23-2010, 01:53 PM   #17
68Cadillac
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Default

The ordering of materials from McMaster went smoothly, but the shipment is delayed in Cerritos, CA because a "MECHANICAL FAILURE OCCURRED" in the UPS shipping hub at 5 am this morning. Looks like the whole facility is down because of it. I hope somebody didn't lose life or limb.
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Old 11-24-2010, 02:46 PM   #18
tyroorosaurswrx
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Subscribed
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Old 11-24-2010, 03:46 PM   #19
Grieby54
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Nice.
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Old 11-24-2010, 04:04 PM   #20
BlobeyeSTi
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PSM

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cool project man Good Luck! I'm debating about putting a lip on mine next spring
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Old 11-24-2010, 08:51 PM   #21
68Cadillac
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Default

UPS came by with some lovin:


Polyethylene (hdpe) Colored Sheet, 1/4" Thick, 24" X 48", Black COUNT TWO
For the Actual splitter

Architectural Aluminum (alloy 6063), 90 Degree Angle, 1/8" Thickness, 1/2" X 1/2" Legs, 8' L COUNT TWO
To add strength to the splitter and make small 90 degree brackets

Static-Dissipative UHMW Sheet, 1/8" Thick, 24" X 48", Black
For filling the gap between the splitter and the front bumper Also to make air dams to to go in front of the wheels.

Sheets of brown paper I acquired at the plant store to transfer my design to the hdpe.

The stripped down frame of my 1968 Cadillac Coupe deVille.


Rivets and hardware. Aluminum tube for custom length spacers.


Detail of the side of the HDPE and the purpose of the aluminum tube (MYO spacer)

I wish I could write that I'll work on this over the holiday but no. Visiting with family is more important. Plus: TURKEY!
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Old 11-24-2010, 11:32 PM   #22
auzy07
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OBP

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Fine fine fine, go eat your turkey. Just be sure to keep us updated on this all goes




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Old 11-25-2010, 12:12 AM   #23
DBLU_RX
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Black

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looks like you used the scissors to sharpen the pencil
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Old 11-25-2010, 01:36 PM   #24
pnutbutta
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CGM

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nice! here's some inspiration, hopefully yours does not catch on fire.

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Old 11-25-2010, 08:07 PM   #25
68Cadillac
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Default

Quote:
Originally Posted by pnutbutta View Post
nice! here's some inspiration, hopefully yours does not catch on fire.
Have you got a hammer?
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