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      01-17-2013, 09:51 PM   #89
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Fibre/Epoxy curing on mold
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      01-17-2013, 09:57 PM   #90
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Cured, cut, dry fitted, pre-drilled, center channel fins attached, sanded and prepped for painting.
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      01-17-2013, 10:06 PM   #91
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Ready for mounting.
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      01-17-2013, 10:07 PM   #92
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As long as you keep the car on the asphalt, you should be fine.
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      01-18-2013, 03:30 AM   #93
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Ready for mounting.
wow that looks amazing.... very nice custom piece!

is it fiberglass? whats it made of ?
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      01-18-2013, 09:57 AM   #94
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wow that looks amazing.... very nice custom piece!

is it fiberglass? whats it made of ?
Fiberglass weeve and carbon fiber set in epoxy over a plastic core for thickness. It came out pretty good. Seb helped out with most of it but was game for the experiment. I will likely work out a next generation solution that will be a two stage process for vacuum bagging. If it turns out nice and is cost effective, I'll likely offer a vacuum process FRP and CF Diffuser solution with and without race muffler option and front splitter for the E46 M3. I'll need to do some testing to see what added downforce it provides over the summer and make adjustments before I build a mold.
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      01-18-2013, 06:30 PM   #95
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Front splitter and diffuser from underneath the car on the lift. 3 months, 2 weeks and 2 days to Watkins Glenn.

There are a few small items left to do, front dive planes (Aka Canards or side vortex generators), closing off some of the holes around the front and rear wheel well, trimming the OEM diffuser to fit the new diffuser, and fitting the new heat shield and exhaust into the diffuser.

A fun project. Much thanks to Mr Seb and the countless hours of being awake at night conjuring this up.

I'm looking forward to more fun with CF or FRP. I just need a workshop and a couple of clients ...
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      01-18-2013, 07:06 PM   #96
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^^
If you leave it like that, it won't pass the sound test
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      01-18-2013, 07:20 PM   #97
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my answer to jgalaxy...
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      01-18-2013, 08:02 PM   #98
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my answer to jgalaxy...
LMFAO, Soooo Cute, but sadly not sure you will fit.
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      01-19-2013, 09:34 AM   #99
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my answer to jgalaxy...
Sweet ride!
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      01-20-2013, 07:26 PM   #100
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Quote:
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Fiberglass weeve and carbon fiber set in epoxy over a plastic core for thickness. It came out pretty good. Seb helped out with most of it but was game for the experiment. I will likely work out a next generation solution that will be a two stage process for vacuum bagging. If it turns out nice and is cost effective, I'll likely offer a vacuum process FRP and CF Diffuser solution with and without race muffler option and front splitter for the E46 M3. I'll need to do some testing to see what added downforce it provides over the summer and make adjustments before I build a mold.
this sounds awesome. most of the diffusers and front lips on the market are basically cosmetic... very awesome of you to start making proper diffusers. i wonder if you can make one for my frog...

something like this.... this ones on a carrera S... not sure if the same thing would fit on my car.
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      01-20-2013, 10:03 PM   #101
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this sounds awesome. most of the diffusers and front lips on the market are basically cosmetic... very awesome of you to start making proper diffusers. i wonder if you can make one for my frog...

something like this.... this ones on a carrera S... not sure if the same thing would fit on my car.
There is nothing cosmetic on this version. LOL. We tried to cover up as much of the undercarriage front and back as possible and contain air in the channels from the rear axles back. The next one will look a little nicer and will use CF.

That diffuser if I recall is $3K. It might fit your ride. But I am sure there is a GT3RS specific application (with the $ figure to go with it) somewhere out there. As soon as I get the mold development and vacuum bagging process down, I'll gladly start looking for guinea pigs (and green frogs)
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      01-20-2013, 10:24 PM   #102
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Quote:
Originally Posted by jgalaxy View Post
There is nothing cosmetic on this version. LOL. We tried to cover up as much of the undercarriage front and back as possible and contain air in the channels from the rear axles back. The next one will look a little nicer and will use CF.

That diffuser if I recall is $3K. It might fit your ride. But I am sure there is a GT3RS specific application (with the $ figure to go with it) somewhere out there. As soon as I get the mold development and vacuum bagging process down, I'll gladly start looking for guinea pigs (and green frogs)
count me in
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      01-20-2013, 10:35 PM   #103
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count me in
Excellent.
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      01-24-2013, 09:32 PM   #104
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Quote:
Originally Posted by jgalaxy View Post
There is nothing cosmetic on this version. LOL. We tried to cover up as much of the undercarriage front and back as possible and contain air in the channels from the rear axles back. The next one will look a little nicer and will use CF.

That diffuser if I recall is $3K. It might fit your ride. But I am sure there is a GT3RS specific application (with the $ figure to go with it) somewhere out there. As soon as I get the mold development and vacuum bagging process down, I'll gladly start looking for guinea pigs (and green frogs)
yea that diffuser costs a ridiculous amount of dough. if i could find something effective for half the price, i am all for it. dont even need it to be in CF. yours looks amazing. so i am wondering, was it you who did most of the work or seb? i am pretty handy around tools but there's no way i can make something like this on my own.
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      01-25-2013, 11:39 AM   #105
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who's going to the open house?
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      01-25-2013, 04:25 PM   #106
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yea that diffuser costs a ridiculous amount of dough. if i could find something effective for half the price, i am all for it. dont even need it to be in CF. yours looks amazing. so i am wondering, was it you who did most of the work or seb? i am pretty handy around tools but there's no way i can make something like this on my own.
It was a collaborative effort - with Seb doing more of the work (his shop and tools). Either one of us could have done it solo, but together it worked well. All mounting and final finishing was Mr Seb.

All you have to be is handy with tools, have the right tools, have a reasonable knowledge of the drag/aero fluid dynamics with respect to automotive, know the automotive platform and know about carbon fiber/fiberglass products and composite mold building. Piece of cake. I've been noodling this one for a long time.

There are three more stages left. 1) Exhaust - Adding the new muffler and exhaust port through the diffuser and heat shielding. 2) OEM Diffuser - Trim down the OEM diffuser and add some rubber piping to make a pro fit around the new diffuser. 3) Make some added fiberglass panels to close of some added areas that add to the parachute effect in and around the wheel wells.
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      01-25-2013, 04:26 PM   #107
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who's going to the open house?
Open house?
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      01-25-2013, 06:10 PM   #108
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Open house?
bmw qc @ sanair

if u wanna go gimme ur details ill email u
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      01-27-2013, 12:00 AM   #109
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bmw qc @ sanair

if u wanna go gimme ur details ill email u
I got the email, but cant figure out if this is a track event, get together, club meeting, or other ...
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      01-27-2013, 09:30 AM   #110
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I got the email, but cant figure out if this is a track event, get together, club meeting, or other ...
track
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