I Made Fender Flares
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08-16-06, 11:46 AM
#8
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There are a few more pics here.
http://www.fmc-inc.net/modules.php?n...ewtopic&t=1404
Basically I wrapped 1/2" ID PVC hose around the tires (orange county chopper style if you've seen them position fenders)
Then wrapped aluminum flashing around the 1/2" hose and trimmed the outer edge to the desired shape.
Next I hand sketched the desired outline on the body.
Tape and cardboard was used to fill gaps and make a dam.
Then Monofoam was sprayed onto the area.
Monofoam was cut down with a knife.
The profile was built up using bodyfill to the desired shape. I left a thick inner and outer edge for strength and for screws into the body.
Next mold release was brushed on.
Two layers of fiberglass mat laid onto bodyfill mold. More on inner and outer edge for strength.
Fiberglass body filler used to smooth it
Part removed from mold for a little sanding.
Drilled screw holes and countersunk them a bit to hide the head.
Paint and screw on.
I'd say the edge of the tires was an inch beyond the stock fenderlip. I cut out the original fenders front and rear for suspension travel clearance.
Ideally I would have created the shape I wanted and made a female mold then laid-up the fender in that. However there was a race on the weekend and that was an extra step I didn't have time for... The purpose of this car is for autocross, not sitting in a garage.
Chris
http://www.fmc-inc.net/modules.php?n...ewtopic&t=1404
Basically I wrapped 1/2" ID PVC hose around the tires (orange county chopper style if you've seen them position fenders)
Then wrapped aluminum flashing around the 1/2" hose and trimmed the outer edge to the desired shape.
Next I hand sketched the desired outline on the body.
Tape and cardboard was used to fill gaps and make a dam.
Then Monofoam was sprayed onto the area.
Monofoam was cut down with a knife.
The profile was built up using bodyfill to the desired shape. I left a thick inner and outer edge for strength and for screws into the body.
Next mold release was brushed on.
Two layers of fiberglass mat laid onto bodyfill mold. More on inner and outer edge for strength.
Fiberglass body filler used to smooth it
Part removed from mold for a little sanding.
Drilled screw holes and countersunk them a bit to hide the head.
Paint and screw on.
I'd say the edge of the tires was an inch beyond the stock fenderlip. I cut out the original fenders front and rear for suspension travel clearance.
Ideally I would have created the shape I wanted and made a female mold then laid-up the fender in that. However there was a race on the weekend and that was an extra step I didn't have time for... The purpose of this car is for autocross, not sitting in a garage.
Chris
08-16-06, 12:55 PM
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Unfortunately is a stock motor, however it is swapped from a GSL-SE with tranny and computer, Racing Beat full exhaust and K&N filter as if that means anything.
However the suspension is full iscracing.net so it handles autocross courses well.
Rear axle is BroncoII 7.5" with 4.10 gears and LSD by the way. Custom panhard bar keeps the roll center height in check. Designed by myself using Race Car Vehicle Dynamics by Milliken and some suspension software. Fun projects that take entirely too much time...
Chris
However the suspension is full iscracing.net so it handles autocross courses well.
Rear axle is BroncoII 7.5" with 4.10 gears and LSD by the way. Custom panhard bar keeps the roll center height in check. Designed by myself using Race Car Vehicle Dynamics by Milliken and some suspension software. Fun projects that take entirely too much time...
Chris
08-16-06, 02:04 PM
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http://www.fmc-inc.net/modules.php?n...iewtopic&t=977
There are some photos and very few details there. If I were you I'd transfer the brackets over to the original locations as used on the RX7. It is a lot easier that way. With some care and research you can fit a panhard bar and the adjustable racing beat swaybar back there. Stock gas tank and all shrouds as found on the SA also fit. However you will get tired of dealing with the shrouds and just leave them off...
Those pictures are before I got the ISCRacing.net springs and shocks but nothing to do with the axle changed.
The broncoII input flange was machined to accept the mazda driveshaft.
The broncoII axles were machined to change the bolt pattern from 5x114.3 to 4x114.3 (ie same as GSL-SE) so my future change to GSL-SE front suspension would mean I had the same pattern front and back.
Also installed a brake proportioning valve.
14" and even 13" Diamond racing wheels fit over the broncoII drums.
The center bore of the broncoII is ~2.5" dia do not many wheels fit, but konig rewinds do as do diamonds. With a little thought you could likely turn down the axle for the proper center bore.
I threw out the stock 1/2" wheel studs and tacked in some 1998 Neon front studs.
OEM clutch type LSD for 7.5" ford work extremely well for a car this light, even with sticky Hoosier Tires.
If you have any specific questions I will try to answer them.
Chris
There are some photos and very few details there. If I were you I'd transfer the brackets over to the original locations as used on the RX7. It is a lot easier that way. With some care and research you can fit a panhard bar and the adjustable racing beat swaybar back there. Stock gas tank and all shrouds as found on the SA also fit. However you will get tired of dealing with the shrouds and just leave them off...
Those pictures are before I got the ISCRacing.net springs and shocks but nothing to do with the axle changed.
The broncoII input flange was machined to accept the mazda driveshaft.
The broncoII axles were machined to change the bolt pattern from 5x114.3 to 4x114.3 (ie same as GSL-SE) so my future change to GSL-SE front suspension would mean I had the same pattern front and back.
Also installed a brake proportioning valve.
14" and even 13" Diamond racing wheels fit over the broncoII drums.
The center bore of the broncoII is ~2.5" dia do not many wheels fit, but konig rewinds do as do diamonds. With a little thought you could likely turn down the axle for the proper center bore.
I threw out the stock 1/2" wheel studs and tacked in some 1998 Neon front studs.
OEM clutch type LSD for 7.5" ford work extremely well for a car this light, even with sticky Hoosier Tires.
If you have any specific questions I will try to answer them.
Chris
08-16-06, 03:11 PM
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Man am I impressed with your projects, outstandingly clean and well thought out. I like the Racecar Vehicle Dynamics reference. That book is the bible of car handling. What other projects have you done with your 7? I'm beginning a long term developement/rebuild of my 82 gsl. I like to see other well done projects, it gives me hope.
Matt
Matt
08-16-06, 07:56 PM
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Ray... Hey thats fine. To tell you the truth the only reason I made them is due to the racing mods I made to get quicker times. One thing leads to another and before you know it your buying 7 or 8 inch wide wheels to fit 13" hoosier slicks and coil-over suspension. All of a sudden the only street tires you can fit stick out an embarrasing amount.
These flares were primarily out of necessity but I put the effort into them so they didn't look too ghetto.
Chris
These flares were primarily out of necessity but I put the effort into them so they didn't look too ghetto.
Chris
08-16-06, 07:57 PM
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i know the stock cars are great, but why must you always knock someones hardwork? everyone knows your stance by now, so it cant be any form of positive criticism to find fault with everything ingenius, or at all necessary.
08-16-06, 08:07 PM
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They may have had the stock lines right but they did not have the stock suspension right for autocross!
It takes a lot of suspension work to keep your outer front wheel this straight up at ~90kph and at the edge of lateral adhesion.
Great times.
It takes a lot of suspension work to keep your outer front wheel this straight up at ~90kph and at the edge of lateral adhesion.
Great times.
Last edited by chris wilcox; 08-16-06 at 08:09 PM.
08-16-06, 08:36 PM
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Originally Posted by matgls23
Man am I impressed with your projects, outstandingly clean and well thought out. I like the Racecar Vehicle Dynamics reference. That book is the bible of car handling. What other projects have you done with your 7? I'm beginning a long term developement/rebuild of my 82 gsl. I like to see other well done projects, it gives me hope.
Matt
Matt
Would be fun to finish though.
http://www.fmc-inc.net/modules.php?n...iewtopic&t=928
There are some images of the 3d model created for porting...
Used too much time on design and didn't have enough for the hands on part.
Last edited by chris wilcox; 08-16-06 at 08:41 PM.
