Recipe for a front splitter

Discussion in 'Car Builds, Projects, Idea's Experiments' started by Mike, Nov 21, 2010.

  1. Mike

    Mike New Member

    May 4, 2009
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    This is a recipe for a front splitter for a 1st Gen MINI. The idea behind this item is to increase front downforce by taking advantage of the higher air pressure both in front of the car (higher over the splitter than underneath) and within the engine compartment (again, a difference in pressure from top to bottom).

    This particular design does not require the links or turnbuckles seen on other designs.

    Ingredients:

    Aluminum 6061-T6511
    Carbon Fiber, Bidirectional (BID)
    Carbon Fiber, Unidirectional (UNI)
    Epoxy, West or Proset
    Rohacell foam, 4lb/cu.ft., 0.38 inch thick
    1/4-28 Stainless steel threaded rod, 60ksi UTS
    -6 Aluminum tubing, 6061-T6

    Step 1: Cut the foam to a pleasing shape:
    foam.jpg

    Step 2: Add carbon fiber. Three plies top and bottom. The middle ply on top should use the UNI with the fibers oriented front to back.

    cf1.jpg


    Step 3: Vacuum bag wet layup for 24 hours. Keep layup at about 75 degrees F.

    vac.jpg


    Step 4: Trim the part, and add aluminum mounting hardware.

    parts.jpg


    Step 5: Mount the splitter using the threaded rod and the tubing. Check for structural integrity by applying approximately 185 pounds of weight to the front edge of the splitter. Bounce up and down a bit to check for deflection.

    standonit.jpg


    Step 6: Trim off lower lip of nose panel and install panel on car.

    finishedunder.jpg


    That's it! Here's a couple of pictures of the finished product:

    finishedall.jpg finishedclose.jpg

    After all of this, I found that I CAN get into my driveway without scraping the splitter on the ground. Nice.
     
  2. Rally

    Rally New Member
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    Impressive work. Great job :Thumbsup:

    What do the two rear mounting points mount to? Subframe?

    All that wheelgap probably helps :p jk
     
  3. Mike

    Mike New Member

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    I added two mounting points to the subframe (welded lugs with 1/4-28 threaded holes).

    Yeah, the wheelgap is bad, but where I live, it saves the car from destruction. Lots of rocks, dead animals, and debris rolling out of pick-up beds around here (not to mention the crappy roads).
     
  4. goaljnky

    goaljnky New Member

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    Way too cool! :Thumbsup:
     
  5. Mr. Jim

    Mr. Jim Mudshark
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    That is sweet! Great gob! I don't think any of them on the market now will hold 185lbs.
     
  6. minimark

    minimark Well-Known Member

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    Good job!!!!
     
  7. Rally

    Rally New Member
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    Ooo nice :Thumbsup:
     
  8. AliceCooper

    AliceCooper Club Coordinator

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    Nice, making any to sell ?? :D
     
  9. goaljnky

    goaljnky New Member

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  10. Mike

    Mike New Member

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    Here's what I wrote in a PM earlier today:

     
  11. goaljnky

    goaljnky New Member

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    Just a thought:

    If you could draw up the plans and a how to, some might be willing to pay for that and source the materials themselves.
     
  12. Mike

    Mike New Member

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    I'd sell the IP, but selling plans is more than I have time to do.
     
  13. mini_racer

    mini_racer Well-Known Member

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    Awesome job and great design, especially since it is turnbuckle free. That thing is nice and strong, makes for a skid plate, supports the bumper cover, and oh yeah......it's a splitter as well. :Thumbsup:
     
  14. Mike

    Mike New Member

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    Yeah, skid plate... <wince> I know it's going to happen. Next time I think I should add a few pieces of sheet metal to the bottom during the layup for use as rub strips.
     
  15. Metalman

    Metalman Well-Known Member
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    Hella nice job Mike......

    The Rohacell foam you used, was that the 71 type? I've been looking at the RC airplane forums for info on skin layups (wings), and that seems to be the name that crops up a lot. I have a project in the back of my mind I've been toying with and seeing you standing on your splitter was impressive. Never knew the 6 layers of Cf would get that kind of strength.

    Chuck
     
  16. CHKMINI

    CHKMINI Club Coordinator
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    I see more machined parts and carbon fiber in Fungo Squiggly's future :D
     
  17. ScottinBend

    ScottinBend Space Cowboy
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    Nice job!

    Is the angle of attack adjustable at all?

    It also looks like it is slightly sloped up instead of down.....by design?
     
  18. KC Jr 54

    KC Jr 54 New Member

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    I would buy one of those if the price is right. Please PM if you decide to do this!

    Sent from my Droid using Tapatalk
     
  19. Mike

    Mike New Member

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    Yes, this is Rohacell 71.

    The angle is about 0.5 degrees pitch up. I was aiming for dead level and got pretty close. As it turns out, the way it is now allows me to pull into my driveway with the splitter about 2mm off of the pavement, so I think I'll leave it alone. There is room for about +/-2 degrees of adjustment, though.
     
  20. BlimeyCabrio

    BlimeyCabrio Oscar Goldman of MINIs
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    May 4, 2009
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    Really impressively strong design. Well done.
     

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