924Board.org

[Physcho]

ok.... so my mechanic laughed when i told him i wanted that. the glass and spoiler is worth more than the car. but i reckon i can build one pretty damn easily in carbon fibre. so if anyone could furnish me with the specs of it, or point me to somewhere (porschev i'm looking in your direction) i'm going to try it. from what I gather carbon fibre is easy to work with and it would be stronger than fibreglass for sure.

and as with all the stupid stuff i decide to do it's all open source. so if this crazy idea pans out expect a guide for all interested.
_________________
People who think they know everything really annoy those of us who do.

[PORSCHEV]

Ok....you can build one yourself quite easy.....Here's how



The first thing I did was make the vents out of some steel pipe...cut the vent and made a few slits in to follow the curve of the hatch. Then welded 2 studs on for mounting. I then drilled the outer part of the window frame where it is only meta;..not too close to the glass. Once I hade that mounted ..I had something to build from.

So even if you started with a metal strip with a couple bolts put through it would give you something to start with.

Now.... I used 2 pieces of plywood (on edge to make the contour) 1 nearest the back of the spoiler...1 at the forward edge. The forward one would obviously be shorter in height due to the angle that the glass inclines.

Once they were in place ( I can't remember how I did that part?) I cover them in bristol board. So now it looked like a flat spoiler. Then I made what would like like a cross sectioned pattern out of bristol board.....used it to produce about 40 more..and taped then all along the frame.
So what you would end up with would be all these mini supports...like studs in a wall! On the ends I slimed the studs down to make a smooth contour transition.

Then cover the ribs/stubs over with masking tape. Now you have a rough spoiler! Cover the car's paint glass etc. because you would now use fiberglass resin and strips of news paper. Don't try cloth as it is too heavy and will colapse the ribs. Let that harden. Next coat...go with resin and matt cloth...or carbon fiber.

Once hardened...remove entire spolier from car and the wooden frame. now you can fiberglass the under side.

I finished it with regular fiberglass filler and bondo products.

If you had some of that cool foam for making shapes.....fellow board member Mikedanger is using it on a front spoiler he is making. I have never used it before but it looks a hell of alot easier then what I did??
_________________
1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.

[Physcho]

interesting. yeah i was going to use the foam to cut out the shape and the coat with carbon fibre ala this guys bike frame http://www.sheldonbrown.com/rinard/howibuil.htm. fibreglass however would be interchangable with carbon fibre, so it might just come down to cost as well. when i get the 944 rear put on my car i'll ask to keep the frame, then i'll have something to experiment with.
_________________
People who think they know everything really annoy those of us who do.

[Peter_in_AU]

If you haven't worked with carbon-fibre before don't underestimate what a pain it can be to work with. Don't want to put you off, just start on a couple of simple curves until you get the hang of it.
_________________
1979 924 (Gone to a better place)
1974 Lotus 7 S4 "Big Valve" Twin-cam (waiting)
1982 924 (As featured on Wikipedia)

Learn to love your multimeter and may the search be with you

[skemcin]

here is a close up of the joint from the glass frame to the spoiler. it be nice if there was a bolt-on version of the 968 wing for the 924 - other than finding a 968 hatch.
http://homepage.ntlworld.com/derrickb/images/968_CS/2.jpg
_________________
924.org (no time to complete)
9249206346 - 89k – new shifter bushings, belts, running well.
9249206347 - 8k – waiting its resurrection, no power at the fuel pump and fuse #7 blows w/power

[Physcho]