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Old 08-13-2019, 06:43 PM   #1
MedicMoses
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Join Date: Jul 2017
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Location: Michigan
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2018 WRX
Pure Red

Default Materials for rear diffuser

I am contemplating building a custom/diy rear diffuser. Knowing the combination of my luck, michigan roads, and mother nature, I want 1 with replaceable vehicle fins. Verus makes a carbon fiber 1 with replaceable fins, but can't/ don't want to spend 1k+. Im trying to decide between ABS/Lexan/Acrylic or sheet metal for the underside/horizontal section. I am going to do the fins in ABS/Lexan/Acrylic.

This will be my first big diy job since doing stereo stuff in the early 2000s.

Im not too worried about weight, its not going to be 1/4" steel, and the car isn't going to be tracked much until maybe late next year.

From what I've found there is a mix of metal, plastic (of some sort), and fiberglass DIY ones out there but there hasnt been much follow up down the road of if they are still running them, made changes, took them off....

Any insight will be greatly appreciated. And as always, if this is in the wrong section, mods please move.
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Old 08-13-2019, 08:05 PM   #2
Scuby04STi
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Rally Blue

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If I wanted to build one on the cheap it would be all made out of aluminum and I would rivet the fins on so it can be drilled out to remove then without removing the rest of it for potential replacement. Just weld small bracing on the backside or have a hot rod shop roll a bead into it (rolling a bead in aluminum would be my lesser choice due to its softness).

I bought raw carbon in a roll to make one and it was like $200 in materials but that takes a lot more time/effort to do correctly.
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Old 08-14-2019, 01:26 PM   #3
speedyHAM
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XP class Impreza L

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Quote:
Originally Posted by Scuby04STi View Post
If I wanted to build one on the cheap it would be all made out of aluminum and I would rivet the fins on so it can be drilled out to remove then without removing the rest of it for potential replacement. Just weld small bracing on the backside or have a hot rod shop roll a bead into it (rolling a bead in aluminum would be my lesser choice due to its softness).

I bought raw carbon in a roll to make one and it was like $200 in materials but that takes a lot more time/effort to do correctly.
I like your idea of aluminum and riveting the fins on. OP- Do what he said.
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Old 08-15-2019, 02:01 PM   #4
MedicMoses
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Pure Red

Default

Thanks everyone! After some further thought and suggestions, looks like im going to do a metal "base" plate with ABS fins. Really learning towards the river route too. Now to design this thing.... Wonder if I can incorporate a rear diff cover into this....

Last edited by MedicMoses; 08-15-2019 at 03:04 PM.
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Old 08-15-2019, 02:19 PM   #5
Scuby04STi
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Rally Blue

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If you plan to use abs for the fins you might use nutsert or weld a nut on the backside of the plate. Over time that abs will get eaten by the rivets and loosen. If you do nutserts its less work to just tighten them back down if they eat the abs up. Just a thought to make work later as easy as possible.

Have fun with the project.
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Old 09-04-2019, 03:12 AM   #6
BugeyeZo
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I made mine out of 1/4 inch abs plastic sheet. If you have any questions feel free to pm me
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Old 09-04-2019, 07:51 AM   #7
Fndragn
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DGM

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I just picked up a boosted beauties version local for $80. It’s a nice piece. I was going to make one myself, but for the price and no effort I was in! It is made from aluminum with riveted on aluminum fins. It’s all powder coated black. It’s super light and appears strong, it was used so I know it has miles on it and has held up great it appears.
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