CARBON FIBRE replacement for those stupid grey plastic splash guards!!!

ScoopED · 04-02-2006, 03:54 PM

G'day,

Well I think I can speak for most EA-ED owners, in saying that "the grey splash guard/sump protectors SUCK!!!!".

Well i'm not 100% sure what their real name is, but for those of you who dont yet know what i'm talking about..... Its that grey plastic thing that goes from just behind the bottom of the front bar to just past the front of the K frame. (i.e. the plastic thing that gets broken off when you park just over one of those concrete parking barriers and then reverse out.....)

Anyway, enough ranting and raving. I'm sick of these things breaking and coming off, and basically just looking crap (more ranting).

My idea is to make a new gurad, capable of sustaining considerable and repeated impacts before breaking.......... (and also to protect my 8.5 litre sump, he he he)

The answer: Carbon fibre

This thread will be a step by step photo filled journy, showing exactly how I am going to go about this.

At the moment I will probabarly be moulding a 4 or 5 ply panel of carbon fibre/epoxy resin, this should be rigid enough.

Shouldnt take me more than a week or 2.

Keep posted.....

Mike

svo347 · 04-02-2006, 04:03 PM

Its actually there to stop air from rushing into the engine bay from underneath and reducing the flow through the radiator.

ScoopED · 04-02-2006, 04:06 PM

Quote:

Originally Posted by svo347

Its actually there to stop air from rushing into the engine bay from underneath and reducing the flow through the radiator.

Well there you go, I learnt something new today..... Either way, they suck, and a replacement must be found.

Mike

svo347 · 04-02-2006, 04:08 PM

I agree , im constantly seeing cars driving around with 1/2 of it hanging off.

efgiar · 04-02-2006, 04:24 PM

yeah mines hanging on with cable ties! go the allmighty cable tie!

chief · 04-02-2006, 05:58 PM

If you want strength then use nomex or high density foam with the carbon.

ScoopED · 04-02-2006, 06:02 PM

Quote:

Originally Posted by chief

If you want strength then use nomex or high density foam with the carbon.

That is a good Idea. A couple of gripes with it tho...... Nomex is expensive, sandwich core material will increase the thickness of the component somewhat. Also the overall flexibility (tho limited) will be further reduced. I have considered using aramid fibre (kevlar) instead of carbon, problem is that it is much harder to work with.

Mike

Racecraft · 04-02-2006, 06:27 PM

it is also there to keep the a/c cooler at low speeds and when you are stopped.. It stops the air that has gone thru the radiator being recirculated over the condensor

NZ · 04-02-2006, 08:21 PM

why not just be careful where you park?

ScoopED · 04-02-2006, 09:54 PM

Quote:

Originally Posted by NZ

why not just be careful where you park?

But that makes no sense..... How else would I fill my "casual worker" days off???? What would I do with my time, other than make expensive overkill parts!!!!

I mean, geez... c'mon......

he he he

Oh and racecraft, I have no air con anymore anyway....

Mike

Racecraft · 04-02-2006, 10:36 PM

A/C is now a roadworthy item so I hear.. Qld DOT have finally cottoned onto the fact that due to the angle of the windscreen it fogs up in the rain with out A/C..

ScoopED · 05-02-2006, 11:27 AM

Quote:

Originally Posted by Racecraft

A/C is now a roadworthy item so I hear.. Qld DOT have finally cottoned onto the fact that due to the angle of the windscreen it fogs up in the rain with out A/C..

ay??? you are pulling my leg right..............

I mean, I dont really care anyway, but I have not heard of this rule.

Mike

Racecraft · 05-02-2006, 11:32 AM

nah, a mate needed to sell his ED and got pinged because the A/C was out of gas. Wether the inspector ws being a tight ar$e I don't know but he had to get it regassed for the RWC.

LUXO_8 · 05-02-2006, 11:43 AM

Quote:

Originally Posted by Racecraft

nah, a mate needed to sell his ED and got pinged because the A/C was out of gas. Wether the inspector ws being a tight ar$e I don't know but he had to get it regassed for the RWC.

damn thats bloody tight!

ScoopED · 05-02-2006, 03:33 PM

Geez, that really does suck.....
I mean, that is a little over the top in my opinion.

Keep a clean windscreen (from the inside), add a little anti fog liquid and you are pretty much good to go, just keep a couple of non rain facing windows down an inch or so.

I have decided on the design, and, starting tuesday I will be forming the surface on which I will be laying 6-7 plys of carbon. I'll be using heavy weight twill weave carbon fibre cloth.

This should provide enough protection for my sump, as you can see, there is very little clearance, it is pretty much the lowest point at the front of the car (reason for 6-7 plys)..... the phone is 104mm tall....

Front of sump

Side of sump

Mike

XRated · 05-02-2006, 04:01 PM

How much is it going to cost you to make? And how much do you charge to make one?

I'm looking forward to the finished product.

LUXO_8 · 05-02-2006, 04:06 PM

me too:P

im gonna need something for my high energy sump

efgiar · 05-02-2006, 04:07 PM

ill prolly need one too, just incase i mount a k-rail again >.<

LUXO_8 · 05-02-2006, 04:08 PM

Quote:

Originally Posted by efgiar

ill prolly need one too, just incase i mount a k-rail again >.<

haha if you never mentioned that i was going to!!!!! :Reverend:

ScoopED · 05-02-2006, 04:11 PM

Quote:

Originally Posted by XRated

How much is it going to cost you to make? And how much do you charge to make one?

I'm looking forward to the finished product.

Figures are not definate yet, but I will probabarly looking at around $40 for the carbon fibre. I cant remember what the resin cost me, it was a while ago that I got it. I'd say maybe $7 worth of resin/hardener.

I'm not sure how much I would charge to make one. If it turns out well, i'll make a propper mould up out of fiberglass, so that I can make copies. Prob sell a carbon one for $80 and a Fiberglass one (with a bottom layer of carbon) for $60 maybe???? Just estimates.

Oh, and there really wouldnt be much (if any) profit there, once you factor in total material cost and the amount of time consumed in designing and tidying the finished product up.

I dont really know about definate $$$ at the moment. Like I said, I'll see how it goes. I'll make it universal fit tho.

It will be larger (and obviously thicker) than the original plastic one.

I was also thinking about making a few copies of my gauge pod (form my keeping you posted...... thread), again, only if it turns out well.

Mike

LUXO_8 · 05-02-2006, 04:13 PM

Quote:

Originally Posted by ScoopED

Figures are not definate yet, but I will probabarly looking at around $40 for the carbon fibre. I cant remember what the resin cost me, it was a while ago that I got it. I'd say maybe $7 worth of resin/hardener.

I'm not sure how much I would charge to make one. If it turns out well, i'll make a propper mould up out of fiberglass, so that I can make copies. Prob sell a carbon one for $80 and a Fiberglass one (with a bottom layer of carbon) for $60 maybe???? Just estimates.

I dont really know about definate $$$ at the moment. Like I said, I'll see how it goes. I'll make it universal fit tho.

It will be larger (and obviously thicker) than the original plastic one.

I was also thinking about making a few copies of my gauge pod (form my keeping you posted...... thread), again, only if it turns out well.

Mike

cool dude, sounds good,

i'd pay around that (not right away but in a couple of months or so) for one....

my car's missing it...

XRated · 05-02-2006, 04:17 PM

Price sounds very reasonable to me.. I don't think mine even has the plastic any more haha!

ScoopED · 05-02-2006, 04:38 PM

Well, I think if I could get atleast 10 people or more interested in this component, then it might be worth a go making a few of them.

It will made to fit a EA to ED sedan, I'm not sure if the front ends of the wagons and fairlanes are the same, and if it will fit, but i'd say it should???

For the moment I will not start up a new "expressions of interest" thread. But I will ask now for atleast what you all think of this idea. And if it is something you would be interested in buying for your car.

Thanks to MADNC_8, XRated and efgiar for feedback so far.

I'll see how this thread goes over the next few days.

Mike

LUXO_8 · 05-02-2006, 04:41 PM

under the metal, a sedan wagon and fairlane are just the same, with the different panels for the fairlane...

Dezza · 05-02-2006, 04:52 PM

Quote:

Originally Posted by Racecraft

A/C is now a roadworthy item so I hear.. Qld DOT have finally cottoned onto the fact that due to the angle of the windscreen it fogs up in the rain with out A/C..

But aircon wasn't standard across the entire range. Do those which didn't originally come with aircon have to get it installed?

By the way, mine doesn't work at the moment either. It has a leak somewhere and needs regassing.

hako · 05-02-2006, 05:26 PM

The A/C does NOT have to be working for a RWC in QLD. The heater is the prime item for demisting....the A/C can lower the humidity of the hot air but it is the hot air raising the temperature of the glass above the 'dewpoint' which stops condensation. Some inspection stations try to rip off customers - always question what they say!!!.

efgiar · 05-02-2006, 05:31 PM

yeah it doesnt need to have ac, not even heat, all it has to do is blow AIR onto the windscreen, hot or cold non the less.

svo347 · 05-02-2006, 06:51 PM

Mate the H/E sumps are made from 3mm steel plate, ive had a few "Knocks" and if hasnt even dented..

snypereb · 05-02-2006, 08:13 PM

When i first bought my car i went to take it off it had 15 screws holding it on!

LG · 06-02-2006, 12:39 AM

Interesting... keep it up!