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Old 02-09-2013, 11:25 AM   #1
I--RIDE--BIKES
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Member#: 279176
Join Date: Apr 2011
Location: Manitoba, Canada
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2006 Sti
SGM

Default Custom Carbon Rear Diffuser Build

Well, Im a big DIY person and had decided to build a diffuser instead of spending $700 of an APR unit. Then I got the bright idea to make it out of carbon!

My process will go as follows:

-Make template
-cut out wood center section then add lexan "wings" to it in order to get the proper curves where it meets the body
-add wings
-add lots of bondo and sand everything to a perfect finish
-paint it

***this will be my plug.

-now use this plug to make a fiberglass mold
-now use this mold to make the final carbon diffuser.

Here are some pics after the first night of work.



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Old 02-09-2013, 11:27 AM   #2
Wreckingball Man
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Chapter/Region: South East
Location: knoxville, TN
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Midnight Black

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Yay!! another DIY diffuser. thanks for posting. Hopefully we can get some more knowledge/perspective. Thinking about doing this myself also.
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Old 02-09-2013, 12:40 PM   #3
husker_nation
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Subscribed! Looks good!
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Old 02-09-2013, 03:19 PM   #4
fiorano94
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Location: Indiana
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14 STi Hatch
WRB

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I can dig it. My biggest problem with the other DIY diffusers is the materials used. Carbon can be bitch to work with, but if you get it right, it's so worth it. Keep us updated.
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Old 02-09-2013, 09:59 PM   #5
HaydenRackson
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2005 WRX
OBP

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Can't wait to see it done!
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Old 02-10-2013, 01:02 AM   #6
thomasubi
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Red

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I'm doing a diy too for my gc8. Mine will look like the golden eagle rear bumper diffuser. A couple of friends already are hating on it tho lol
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Old 02-11-2013, 10:01 PM   #7
I--RIDE--BIKES
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Over the last few days I have been furiously applying many layers of bondo, primer and wood filler to make the plug as smooth as a (insert something of great smoothness). Now im almost done the primer and wood filler stage and will soon give it a gloss paint job to finish off the plug. Im hoping to get the carbon fiber fabric ordered in the next couple days as well.

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Old 02-11-2013, 10:04 PM   #8
CobbWRX
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Quote:
Originally Posted by I--RIDE--BIKES View Post
Over the last few days I have been furiously applying many layers of bondo, primer and wood filler to make the plug as smooth as a (insert something of great smoothness). Now im almost done the primer and wood filler stage and will soon give it a gloss paint job to finish off the plug. Im hoping to get the carbon fiber fabric ordered in the next couple days as well.

about how much does this weigh?
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Old 02-11-2013, 10:05 PM   #9
I--RIDE--BIKES
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Not sure. 15 lbs? But remember this isn't the final product, its the plug that is used to create the mold with in turn is used to make the final carbon fiber piece.
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Old 02-11-2013, 10:10 PM   #10
bmw325ix
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looks awesome, Ive been reading up on carbon fiber myself
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Old 02-18-2013, 11:28 PM   #11
I--RIDE--BIKES
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Location: Manitoba, Canada
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2006 Sti
SGM

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Update:

Got the second plug done today and sprayed both of them with an epoxy paint to give it a hard finish. Next I will wax the plugs with mold release wax before I lay down the fiberglass for the mold.



**Edges are not all cut to the finished part size. Once carbon comes out of the mold in will be trimmed to fit.
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Old 02-19-2013, 04:18 AM   #12
WhozNext
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SWP

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Looks good so far
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Old 02-20-2013, 10:31 AM   #13
wrxiting
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John john tuned

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Nice friggin work. Wish I had that much talent. Can't wait to see the final.
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Old 02-20-2013, 11:25 AM   #14
I--RIDE--BIKES
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2006 Sti
SGM

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Thanks. Today I'm sanding both plugs with 600 then 1500 grit and finishing them with a polish. Once I'm done that I will apply the mold release wax. Then it's mold making time!
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Old 02-20-2013, 01:55 PM   #15
myblusti
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blue/gold

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great job. looks very good.
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