Reserved for updates...
Phase 2 - Side Splitter fabrication and mounting using ABS - COMPLETE
Phase 3 - Rear Diffuser Template - IN WORK (Rear fins complete)
Phase 4 - Rear Diffuser fabrication and mounting using ABS (will likely melt near exhaust) IN WORK (Rear fins complete)
Phase 5 - Rear Diffuser fabrication and mounting using Aluminum sheet metal painted flat black
EDIT 7/6 - Progress on Phases 2 & 3...
So I made a little progress on my track aero project over the 4th of July holiday break...
- Drove out to Rancho Dominguez and purchased (qty 3) sheets of 1/8" ABS from CALSAK Plastics. I wanted to get the 1/4" thick sheets, but they're too rigid and couldn't be rolled up so they wouldn't fit in my wife's Toyota Rav4. I bought a bunch of extra in case I mess up and b/c I plan on making a smooth bottom for the entire car (less a few key cutouts for proper air flow around the engine, downpipes, rear diff, and exhaust).
- Purchased some 3M carbon fiber vinyl wrap (ordered from Amazon
here)
- Cut out side splitters and approx sized pieces for rear diffuser
- Went to Ace hardware in Torrance and purchased a bunch of different fasteners, washers, nuts, tee nuts, rivets, and L-brackets for mounting the splitters and rear diffuser.
- Created template for rear diffuser side pieces, but I'll probably tweak it a little b/c after reviewing the pictures I took I think the edge near the rear tire should be more straight and a little less rounded.
Pretty happy with how similar my 1st cut is compared to the VRS piece. When I cut it from ABS I'll make the left edge more straight near the tire / wheel well.
Next steps:
- Optional: I'm considering using my heat gun to create a 90 deg bend on the inboard edge of the side splitters. This would have a major impact while tracking as it creates a wall for the air under to car to flow and not allow it to escape on the sides between the front and rear wheels. Downside is that it would reduce ground clearance and impact daily driving. I may compromise and make two sets of side splitters; one set for track use and one set for cosmetics / daily driving. What do you guys think?
- Remove side skirts from car and mount side splitters using tee-nuts. Tee nuts will be riveted to inside of side skirt for easy install and removal of the splitter. Basically, the tee nut is fixed on the inside of the side skirt, so when the splitter comes on and off, the only hardware installed/removed is the fastener and washer. Planning on using ~6 tee nuts on each side.
- Wrap side skirts in 3M carbon fiber vinyl (still waiting for this to arrive from Amazon).
- Install black auto door trim around outer edge of side splitters (like the beveled edged shown on the side splitters installed on Neema's black E92 shown in my original post).
- Continue creating the template for the rest of the rear diffuser.
UPDATE 7/31
Finished, wrapped and mounted the first part of the rear diffuser. Side splitters are complete and ready to be wrapped and mounted; I just ran out of time this weekend. Too much work
EDIT 8/4 - Phase 2 COMPLETE
So this weekend I finally finished off the side splitters and overall I'd give myself a 7/10 with the finished product.
1) I used this
DIY guide to remove the rocker panels (aka - side skirts).
2) I managed to break 6 of the white, plastic M3 clips (note the 335i uses the rectangular yellow clips). I wasn't too worried since I figured I could just pick up a couple of new ones from the dealership, but they didn't have any in stock so it looks like I'll get to drive around with no rocker panel on the passenger side until Wednesday.
For comparison, the left clip is broken and the right is good-to-go.
You can see only 4 of the 10 plastic clips are left on the passenger side rocker panel below, because I had to use some of the good ones from the passenger side to complete the driver side before re-installing.
3) The heat gun was key to help bend the black plastic door trim around the tighter radii of the front and rear end of the splitters. The trim gives it a little more weight and a nice finishing touch.
Ordered the trim from
here. 15' is enough to do two splitters.
All said, I'm happy with how it turned out.
If I were to do it all over again, I'd go back to CalSak Plastics with my father-in-laws truck and use the thicker, 1/4" ABS. Because it's twice as thick, the sheets couldn't be rolled like carpet and didn't fit inside my car. Oh well. I have lots of extra. Next up is finishing the rear diffuser and then onto the front splitter. Oh, and make ChrisE92 a pair of rear fins.
