Front splitter for the track

Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!


Aim: To make a front splitter

http://en.wikipedia.org/wiki/Diffuser_(automotive)
As the front of the car slows down the air without a diffuser, this is the ideal place for an inlet. A splitter is commonly used here, serving to increase the amount of downforce at the front of the car. The airstream is brought to stagnation above the splitter by an air dam, causing an area of high pressure. Below the splitter, the air is redirected away from the stagnation zone and is accelerated, causing the pressure to drop. This, combined with the high pressure over the splitter creates downforce. The larger the area of the splitter, the more downforce is generated

Required:
Safety equipment
- Safety glasses ( I had a face mask)
- Gloves (aluminium is one of the fastest heating metals)
- Proper footwear
- Ear plugs or ear muffs ( angle grinders and drills can be quite loud)

Tools
- Angle grinder with stand – with 2 x aluminium cutting disc
- Jigsaw
- Drill with wood and metal drill bits
- Dremel with metal cutting disc
- Socket set 10mm - 14mm
- Tape measure
- Marker

Materials
- Black paint, I choose flat black but you can pick whatever
- Plywood 2400mm x 1200mm x 12mm
- 2 25cmx25cm 8mm aluminium sheets
- 2 4mm Bottlescrew jaw & jaw
- Wire eye strap
- 3mm aluminium L brackets
- 20 m8 x 40 cup head bolts
- 8 m8 bolts
- 52 m10 washers
- 3M automotive tape or pot rivets
- Garden edging

Cost roughly $192

Can be done cheaper if you are able to find off cuts of aluminium instead of getting new pieces cut off.


Angle grinder
http://img217.imageshack.us/img217/8717/img2556zg.jpg

Jig saw
http://img84.imageshack.us/img84/8190/img2598kg.jpg

work space
http://img138.imageshack.us/img138/8813/img2595u.jpg

3m tape
http://img402.imageshack.us/img402/5518/img2613qj.jpg

aluminium sheet
http://img802.imageshack.us/img802/4845/img2551r.jpg


http://img85.imageshack.us/img85/2251/img2553bi.jpg


Steps:

Step 1:
Locate and remove your stock tow hooks which are positioned on your front chassis rails, at the same time see how much room you have for the front splitter mounts. There should be three 14mm bolts on each side.

Step 2:
After getting a rough idea of space, mock up your splitter mount on cardboard. Cut out your cardboard mount and test fit it on the car itself.

http://img688.imageshack.us/img688/6472/img2552nb.jpg

Step 3:
Once you’re happy with the mock mount, trace the mount onto the sheet of aluminium and start cutting out the mount with the angle grinder. Best to take it in sections and let the aluminium cool down.

http://img27.imageshack.us/img27/5193/img2557kw.jpg

http://img23.imageshack.us/img23/7343/img2558f.jpg

http://img580.imageshack.us/img580/9755/img2559z.jpg

Step 4:
Proceed by drilling the holes for the chassis rail bolts, I found it easier to drill two holes for each bolt hole and used the dremel to cut in between. As you can see Ive made the hole longer instead of a fixed hole to help with removal of the bumper and also allowing height adjustment of the splitter itself.

http://img220.imageshack.us/img220/905/img25791.jpg

Step 5:
Test fit the mount onto the car once all the chassis bolt holes are drilled and cut. I had to widen the holes a few times to get it sitting perfect.

http://img809.imageshack.us/img809/9787/img2584m.jpg

Step 6:
Cut the aluminium L bracket into four 40cm long pieces and place them along side your splitter mount. Mark up the holes where you want to drill into. (I placed those holes 5cms apart)

http://img10.imageshack.us/img10/8278/img25792.jpg

http://img220.imageshack.us/img220/9315/img2592s.jpg

Step 7:
Drill the holes in both the L brackets and the splitter mounts and bolt them together. (I used a drill bit slightly bigger then my bolt just to allow for any errors). When you are happy with the way it is sitting continue to drill another 16 holes between both splitters for the plywood to be bolted onto the splitter mount.

http://img259.imageshack.us/img259/4643/img2594cp.jpg


Step 8:
Remove your bumper and place it on the plywood and trace around the bumper allowing roughly a 10cm boarder. Once you are happy with where it is sitting move on to cutting up the splitter with the jigsaw. I made mine a bit bigger so shave down later once it is mounted on the car just in case it was too small.
I also planned on having the splitter go under the sump but with the K swap it wouldn’t allow it. So i proceeded to just cut the sump part completely off.

http://img100.imageshack.us/img100/316/img2607t.jpg

Step 9:
Bolt the splitter mount onto the car and place the plywood under and position it to your liking. Mark up where the holes are to drill on the plywood and mark up where the base of the mount will sit so you can secure it on.

http://img201.imageshack.us/img201/6688/img2604i.jpg

Step 10:
Drill holes for the mount on the plywood (I ended up with 10 holes on each side) and secure the two together.

http://img20.imageshack.us/img20/9254/img2608d.jpg

http://img14.imageshack.us/img14/4913/img2610w.jpg

Step 11:
By now it would look alot more like a splitter, go and mount the splitter onto your car with the front bumper on. Take the garden edging and place it around your front bumper and on the splitter. Mark where the splitter is sitting and cut off any excess length.

http://img42.imageshack.us/img42/876/img2609x.jpg

Step 12:
To secure the garden edging you will need L brackets, nut and bolts and double sided tape(or pot rivets).
Instead of buying small L brackets I used the long left over L bracket piece I had and cut out 5 separate pieces. I then drilled a hole in each one and double sided tape it onto the garden edging. Place the edging on the outline marked before on the plywood and drilled my final 5 holes.
Secure everything on and once again mount back onto the car.

http://img190.imageshack.us/img190/6953/img2611f.jpg

http://img836.imageshack.us/img836/1200/img2612yw.jpg

http://img696.imageshack.us/img696/6484/img2616xs.jpg

Step 13:
Position and install the bottlescrews and wire eye strap on the bumper and front splitter with the screws provided, this is for added strength of the splitter when down force is applied.

http://img201.imageshack.us/img201/8581/img2617l.jpg

Step 14:
When you are happy with the splitter and nothing else really needs to be done, remove everything off the plywood and start prepping your plywood for painting. I filed down the edges to make them smooth and just wiped down the surface but you can always lightly sand it.

finish by spraying it in the colour of your choice, then assemble it all back together


http://img100.imageshack.us/img100/7051/img2623fz.jpg

Mine weighed in at

http://img38.imageshack.us/img38/4709/img2627i.jpg

Final product

http://img152.imageshack.us/img152/6227/img2699j.jpg

http://img716.imageshack.us/img716/6...itterfront.jpg

Tips:
Always take a break to clean up every so often
Found it easy to grind down rough edges of the aluminium with the dremel w/cutting tool
Drill a hole bigger than your bolt to allow for errors
Always measure and mark and double check after every hole is drilled.

please overlook any bad spelling or grammer :/

comments and criticism welcome :)

Awesome write up!

Product looks good. Keep up the good work

Thanks man, also for the inspiration after seeing yours :thumbsup:

http://i837.photobucket.com/albums/z.../blackclap.gif

Very good DIY mate (Y)

Expect to get bombarded with rep.

thats some ghetto shit, but ingenious (Y)

Thanks for the write up :thumbsup:

I need to do this soon.

building mine 2morrow, thanx

Quote:

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Originally Posted by G-Stick

Always take a break ....

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typical duy LOL!

Quote:

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Originally Posted by mocchi

http://i837.photobucket.com/albums/z.../blackclap.gif

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haha typical Oscar xD

Quote:

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Originally Posted by tiksie

Very good DIY mate (Y)

Expect to get bombarded with rep.

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Quote:

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Originally Posted by butterfingers

thats some ghetto shit, but ingenious (Y)

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Thanks guys, I am all for ghetto :thumbsup:

Quote:

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Originally Posted by TypeS

Thanks for the write up :thumbsup:

I need to do this soon.

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Quote:

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Originally Posted by Riced_Civic

building mine 2morrow, thanx

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Nps, post them up here when your done :D

Quote:

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Originally Posted by longers

typical duy LOL!

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Haha.. i dont take too many breaks lol.. ask the guys xD

ahh shiet finally a DIY no some motivation to make one for the eg thanks for write up very good

Very nice DIY splitter

Nice write up.. Now I'm waiting for a write up for a rear diffuser :p

amazing haha

Awesome.
same goes with me. after seeing pics of BYP sponsored cars and their cars.
i decided that i will be making mine out of fiberglass and Carbon.
i'll also be trying to make a rear diffuser aswell.
i'll also be making a template out of Alluminium Sheets 3-5mm thickness.
then build my own moulding and then the finial product.
hope i'll be able to get this done before the Nationals.
still looking for the best prices on fiberglass cloth and Carbon cloth. Hopefully i find some good deals.
but if i cant find a good deal on Carbon cloth then i might just rock it with fiberglass lols. see how my luck goes.

great work man keep it up bro.

i reckon a fibreglass splitter will be to fragile and definitely wouldn't last long.

Would you lay it up yourself?

Quote:

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Originally Posted by jdm_typer

i reckon a fibreglass splitter will be to fragile and definitely wouldn't last long.

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i think it should be decent.
as i'll be using 3 types of fiber compounds.
for the front - top layer will be carbon fiber, middle will be fiberglass and bottom layer will be kevlar.
for the rear - top layer will be kevlar, middle will be fiberglass and bottom layer will be carbon fiber.
carbon fiber - 2x2 twill with decent grading.
kevlar - 2x2 twill with decent grading.
fiberglass - Mats with around 200 - 300gm grading.
pending on how many layers of each type im going to use will be stiff and strong enough

or you can go for something a lil cheaper.
example: 3mm MDF, polyboard or aluminium etc...
use that as a base and fiberglass 1-2 layers all round.

only reason why im picking the 3 fibers is why not try something different. since its a DIY and im still spending money. might try make the most out of it. you never know. it might turn out really good. :)
also it will be light aswell :)

just make sure u wear safety gear and gloves.
and have fun

Quote:

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Originally Posted by Havocwreaker

Would you lay it up yourself?

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yeh i'll be giving this ago.
since i know how to fiberglass i dont see y not try it out. (atleast knowing the basic)

Quote:

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Originally Posted by na-118

ahh shiet finally a DIY no some motivation to make one for the eg thanks for write up very good

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Thanks man, decided to do it on my days off.. lucky it was good weather or else it would havent gone ahead.

Quote:

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Originally Posted by EG5

Very nice DIY splitter

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Thanks Yonas

Quote:

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Originally Posted by atari

Nice write up.. Now I'm waiting for a write up for a rear diffuser :p

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Nah i cbf making a rear diffuser.. though i will be making front canards soon

Quote:

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Originally Posted by Ryan_Chandler

amazing haha

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:thumbsup:

Quote:

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Originally Posted by mytfoz

Awesome.
same goes with me. after seeing pics of BYP sponsored cars and their cars.
i decided that i will be making mine out of fiberglass and Carbon.
i'll also be trying to make a rear diffuser aswell.
i'll also be making a template out of Alluminium Sheets 3-5mm thickness.
then build my own moulding and then the finial product.
hope i'll be able to get this done before the Nationals.
still looking for the best prices on fiberglass cloth and Carbon cloth. Hopefully i find some good deals.
but if i cant find a good deal on Carbon cloth then i might just rock it with fiberglass lols. see how my luck goes.

great work man keep it up bro.

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Too much time on your hands haha :D i have no idea what i am doing with fibreglass.. post up a diy on it, would be interesting to learn.

Quote:

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Originally Posted by jdm_typer

i reckon a fibreglass splitter will be to fragile and definitely wouldn't last long.

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yeaa.. my splitter copped a beating when i spun off, still in good shape just abit of paint missing :D

What a sick idea. I'm gonna use it to mount my bash plate/splash guard

Quote:

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Originally Posted by G-Stick

Too much time on your hands haha :D i have no idea what i am doing with fibreglass.. post up a diy on it, would be interesting to learn.

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lols i dont really have that much time on my hands lols.
EG is finished but i havent even put everything back together yet lols
i was gonna make a front splitter and rear diffuser ages ago but then i been too lazy.
since u wrote a DIY its on like donkey kong now LOLs :P
its all about show and tell along with fun and games.
just like the day when my eg was stuck on trailer AHAHAH killed the underbody a little and bashed the front rims. :( but fun times
i'll post a diy soon. once i get all the materials ready.

Quote:

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Originally Posted by trism

What a sick idea. I'm gonna use it to mount my bash plate/splash guard

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yup for sure it is.
might want to look at different materials.

haha it sure was stuck.. lol

ahahaha BAD lols.
and it was my first time towing my car.
i towed a boat before but never reversed it ahaha.
its normally i tow my friend reverse ROFL.

fibre glass would get damaged a lot easy and chip ect, would look awesome tho

Quote:

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Originally Posted by jdm_typer

fibre glass would get damaged a lot easy and chip ect, would look awesome tho

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damage - for sure it will but i guess have to see how many layers i end up using. the thicker the more it can handle. and yet be lighter than wood.
either way might aswell give it a shot huh. :)
but then for sure it will get chips. thats y i think going for d kevlar and carbon 2x2 twill weave will be a little more durable.
for sure break if stack or spin out

I have 2 sq/m of carbon if you want it

Any signs of burning or fire from the heat of extractors. looks good anyway

Was any difference felt at the track. ( looks like it was Winton )

Quote:

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Originally Posted by Dart

Any signs of burning or fire from the heat of extractors. looks good anyway

Was any difference felt at the track. ( looks like it was Winton )

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Duy has k-series so his exhaust manifold goes from the back so it sits pretty far from it, I believe.

Plywood is basically dry, it might ignite a flame from 290degree's (comming from this wood book). So it's pretty safe. It's also quite stronger than normal wood too, lets say a 10mm plywood would be stronger than 25mm of wood, both being solid.

Duy won't probably even feel the difference lol but the front splitter does its part, it helps for more downforce. It doesn't give you the extra 50kw or doesn't make you turn like Tarzan yamada.

Great DIY bro thanks for the effort, +1 rep.

Quote:

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Originally Posted by DC2-PWR

Duy has k-series so his exhaust manifold goes from the back so it sits pretty far from it, I believe.

Plywood is basically dry, it might ignite a flame from 290degree's (comming from this wood book). So it's pretty safe. It's also quite stronger than normal wood too, lets say a 10mm plywood would be stronger than 25mm of wood, both being solid.

Duy won't probably even feel the difference lol but the front splitter does its part, it helps for more downforce. It doesn't give you the extra 50kw or doesn't make you turn like Tarzan yamada.

Great DIY bro thanks for the effort, +1 rep.

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Most of us can feel the difference from a strut brace so I think it was a valid question to see what the driving impressions of the splitter, was . I have had other Honda member report a drop in lap times from a rear wing so would be nice to see if all the effort was worth it or was it for toss value.

50 kw ,,What a wancar

Quote:

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Originally Posted by Dart

Most of us can feel the difference from a strut brace so I think it was a valid question to see what the driving impressions of the splitter, was . I have had other Honda member report a drop in lap times from a rear wing so would be nice to see if all the effort was worth it or was it for toss value.

50 kw ,,What a wancar

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I'm sorry dude I may have constructed my previous post in way that probably got you worked up.

In conclusion its definetly worth it, I also have a front splitter recently made. Results arn't wow but it helps.

No probs ��

Nice DIY!!! Looks good!

Here's what mine looks like. Def feel a difference with it!

http://img40.imageshack.us/img40/618...side124124.jpg

This is wicked! Nice write up (Y)

Nice diy!

nice, will be making one on the weekend!

I LOVE IT! Nice diy. i'm in the middle of making one now too! just want your opinion - do you think 5mm 5083 aluminium is strong enough for the mounts?

hey mate! i'm halfway through making my splitter =] what do you think about using the bolt on spot for the reinforcement bar as the mounting position? can't seem to find anywhere on an ek to mount

Reviving old thread.. I recently built my splitter. Anyone have ideas on what I can use at under edges of the splitter at the front to protect it from the scraps?

Quote:

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Originally Posted by doosra

Reviving old thread.. I recently built my splitter. Anyone have ideas on what I can use at under edges of the splitter at the front to protect it from the scraps?

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Show us a pic! Keen to see on an EP3!

just let it scrape. Its a piece of wood lol

Looks shit when u let it scrap cause your get all fury wood bits on the edges.. problem solved http://tapatalk.imageshack.com/v2/14...fec6d9ea19.jpg

Great write up. Has anyone tried using aluminium sheet metal with some kind of lip like this one http://pages.ebay.com/link/?nav=item...d=221560187887
I'm thinking about buildin one for the ek to try and prevent the front end from lifting and getting too light around the 180kph mark.

Quote:

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Originally Posted by doosra

Looks shit when u let it scrap cause your get all fury wood bits on the edges.. problem solved http://tapatalk.imageshack.com/v2/14...fec6d9ea19.jpg

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What did you use?

Go Clark Rubber.. they have this pinchweld pvc strip u can buy

Nice. I'll have to check it out then