Carbon Spoiler Build Thread

[6th-Element]

Here are some progress pics to show you all how a spoiler is made from scratch (at least how I make one, anyways)

First step, I protect the decklid with layers of packing tape and wax paper

01 Prepping the decklid.jpg

Second step, build a backdrop for the rear of the spoiler

02 Setting the rear profile.jpg

03 Setting the rear profile 2.jpg

Laying down the fiberglass for a base on the deck and the rear

04 Glassing the rear profile.jpg

05 Glassing the rear and the base.jpg


Damn near impossible to logically load pics....

[BlknBlu]

really cool. A lot of folks will find this extremely interesting.

Bruce

[6th-Element]

Applying the resin to glass





Building the front profile of the spoiler

[6th-Element]

Now we have poured the xpanding foam






Removed the profile barriers , now it looks like a NASCAR Viper





First trim and mark out a profile of the curve



Now a template that can be flipped from side to side to make sure it is the same on each side



Now a quick Photoshop to see if looks good

[6th-Element]

Now the trimming and shaping begins....









Now cut out a slot so you can see behind you in the rear view mirror







Checking it out in the Dark!



Now sand some surfaces down





Getting the final profiles sanded out of the foam

[6th-Element]

Now applying resin and a layer of glass over the foam to finish the piece off

[Torquemonster06]

Very nice. Super labor intensive. Subscribed.

[DreadLox]

I love seeing projects come together. Way to go with getting it done, looking forward to more pics later!

[SmoknTires]

Wow. Now that's cool. Can't wait to see the finished product. Hope the splitter is project #2! ;.)

[6th-Element]

Here are some pics with the plug painted black after a rough trim. After this I will be doing a good 5-8 hours of fine sanding and finishing, then pulling a mold to pop these babies out in Carbon Fiber.

Matching Splitters... Definitely!

[Canadian venom]

[J TNT]

Nice option for the coupe guys .

[commandomatt]

Have to ask a question.

While I can definitely appreciate the work that is put into something like this.....shouldn't there be a fair amount more to it ?

In other words, whats done to ensure that this design does whats intended when at speed ? When you bring this car up to 100 mph +....how does this spoiler change the way it feels ? When these speeds are reached, even the slightest change to the overall design of the car will start making a difference

It may push the rear end down but it could also make the front end feel loose. Could have a very negative result on how the car reacts. Matching splitters is mentioned, but again...it seems like these parts should be very carefully matched to each other

When these ground effects, wings and spoilers are designed at the factory level I would suspect that they are in fact tested in a wind tunnel or similar to see how they change the cars characteristics when the speeds increase

Not trying to start any crap here....just curious more than anything

Matt

[6th-Element]

MAtt,

YEs, one should always combine a splitter with a rear aero device such as a wing, and to a lesser extent with a spoiler. The ACR wing will create over 1000 lbs downforce at 150 mph, a TA spoiler 600.

The spoiler spoils the airflow and decreases lift which correspondingly makes downforce.

A car without a spoiler = fast
A car with a spoiler = faster
A car with a low downforce wing = fastest
A car with a high downforce wing = Faster in the corners , slower on the straights

[The_Greg]

Have to ask a question.

While I can definitely appreciate the work that is put into something like this.....shouldn't there be a fair amount more to it ?

In other words, whats done to ensure that this design does whats intended when at speed ? When you bring this car up to 100 mph +....how does this spoiler change the way it feels ? When these speeds are reached, even the slightest change to the overall design of the car will start making a difference

It may push the rear end down but it could also make the front end feel loose. Could have a very negative result on how the car reacts. Matching splitters is mentioned, but again...it seems like these parts should be very carefully matched to each other

When these ground effects, wings and spoilers are designed at the factory level I would suspect that they are in fact tested in a wind tunnel or similar to see how they change the cars characteristics when the speeds increase

Not trying to start any crap here....just curious more than anything

Matt

I have thought this often - Isn't there someone out there in Viper land who is a CFD expert who could analyze these designs for us? But my gut reaction is that these devices won't have any major negative characterists. I tihnk this spoiler will generate downforce, but it might create more drag than one designed in a wind tunnel or virtually through CFD. As far as being unsafe (lightening the front end at speed), while thats possible I don't think this spoiler design will generate as much downforce as an ACR rear wing, so it might not be as much of an issue.

The point is that you're right - its somethign that should be considered probably. However, I don't think this design will produce very large amounts of downforce.

[SSGNRDZ_28]

Looks great so far. What is your plan for attaching this to the decklid?

[SSGNRDZ_28]

I have thought this often - Isn't there someone out there in Viper land who is a CFD expert who could analyze these designs for us? But my gut reaction is that these devices won't have any major negative characterists. I tihnk this spoiler will generate downforce, but it might create more drag than one designed in a wind tunnel or virtually through CFD. As far as being unsafe (lightening the front end at speed), while thats possible I don't think this spoiler design will generate as much downforce as an ACR rear wing, so it might not be as much of an issue.

The point is that you're right - its somethign that should be considered probably. However, I don't think this design will produce very large amounts of downforce.

I have resources for CFD analysis but ideally the entire car would need to be modeled in CFD to get the whole story (tons of work). It would be cool to have though and once the base model was complete parts could be added and swapped fairly easily. Maybe someone at SRT can donate the car model? Wishful thinking, but it would be a powerful tool for product validation.

[ACR Steve]

Damn looks good but looks like a crazy amount of hours

[The_Greg]

I have resources for CFD analysis but ideally the entire car would need to be modeled in CFD to get the whole story (tons of work). It would be cool to have though and once the base model was complete parts could be added and swapped fairly easily. Maybe someone at SRT can donate the car model? Wishful thinking, but it would be a powerful tool for product validation.

Yeah, that base model would be one of the initial hurdles. Then also . Hmm, now we just need someone with a 3d scanner... This is getting more complicated! haha.

I forgot to mention also that I really like the way this spoiler looks and am very appreciative of the work you're doing, 6th-element!

[Viper Girl]

Damn near impossible to logically load pics....

Steve some people were having problems with pix from AOL, but most have fixed the issue by using firefox or chrome. Maybe use a different browser?

[Revolution]

Why not just model the Gen 5 spoiler and reverse engineer?

[The_Greg]

Why not just model the Gen 5 spoiler and reverse engineer?

Because isn't it like $3k?

The materials he put into this project so far are probably much less expensive. Though i do wonder how well a gen V spoiler would fit on other gens. Maybe one of the dealers can take one off and set it on a different gen for us

[SSGNRDZ_28]

Yeah, that base model would be one of the initial hurdles. Then also . Hmm, now we just need someone with a 3d scanner... This is getting more complicated! haha.

I have the scanner too; just not enough time for the base model!

[6th-Element]

Looks great so far. What is your plan for attaching this to the decklid?

I will post up the underside soon, it is 2 surfaces, one that is approx 2" x 70+" and one that is approx 1.25 " x 72" lots of surface area to mount with any of the 3M double sided body molding tape (not the hardware store stuff but the stuff the OEM's use), or PL Bonding adhesive or Windshield adhesive, all 3 are items that any body shop can use. NO DRILLING REQUIRED!

[6th-Element]

Because isn't it like $3k?

The materials he put into this project so far are probably much less expensive. Though i do wonder how well a gen V spoiler would fit on other gens. Maybe one of the dealers can take one off and set it on a different gen for us

It wouldn't fit at all, curvature at the back is different and angle if deck lid is different and at differing slopes.

This one fits this car like a glove (feels like it snaps into position just laying it on the deck lid)