S4 sport undertray (yes i actually made one)
 

i had been reading a bunch of post with people talking about finding a company to make a repop of the sport undertray, but none ever really came around, so seeing how i have made mutiple parts for my car and i have been doing sheet metal fab for 5+ years i figured i might as well give it a try. i apologize for the crappy pictures all i had at work was my phone.

i started with a cardboard cut out to figure out the curves and plot them in cad so i could punch it out on the NC punch press and proceeded to punch one from some .060 5052 alum then put a 8 degree bend in it to kinda match the subframe
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo12301523.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo12301523.jpg" border="0" alt="Photobucket"></a>

spacers machined from .750 alum round i turned the ends down to .625 and abotu .060 deep the countersunk the ends for M6 flat heads
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo02021027.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021027.jpg" border="0" alt="Photobucket"></a>

then proceeded lots of cutting of templates to fabricate the "legs" by the rear a-arm mounts and this is what i ended up with, the hinged door is still a up in the air idea not totally sure about it yet.

<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo02021639.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021639.jpg" border="0" alt="Photobucket"></a>
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo02021639_1.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021639_1.jpg" border="0" alt="Photobucket"></a>
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo02021640_1.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021640_1.jpg" border="0" alt="Photobucket"></a>
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo02021658.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021658.jpg" border="0" alt="Photobucket"></a>
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo02021659.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021659.jpg" border="0" alt="Photobucket"></a>



--JOE

That...is awesome sauce. Though I assume the 'trap door' is to facilitate oil changes without removing the tray?

That looks like a pretty good piece you built there. I think I would leave out the door and just have it as more of a hole like the OEM piece is. Of course, then the edges may be sharp, but I guess that same problem may exist right now anyway.

You may be on to something, but I'm sure you know how it goes around this place. I myself wouldn't buy something like this until my car is back on the road - hopefully late this year.

door for draining oil?

The door is for draining oil. That's right where the drain plug is on the oil pan.

correct the door is for changing the oil. it would be cool to sell a few these to fund my larger fab project of a twin turbo bridge port series 4 turbo motor with a custom alum intake and GSXR throttle bodies

I think you'd need to sell more than a few hahaha

But awesome fab work!

I've not heard of this sport tray before. What is it supposed to do? I'm guessing it helps with air flow under the vehicle but I may be wrong. Was there a S5 version?

the s4 and s5 versions where the same as well as the undertray. this is a belly pan.

I would be interested, depending on final price with shipping and what finish would it have? pictures look a bit blurred cant tell

anyone have a picture of the oem tray for comparison?

Not the best but its all I got. Stock is really thin material compared to the one shown here. Aparently adding it is a perceptible gain in mpg...

not the best but its all I got

i would be interested in one. can you still run the lower sub frame brace with it on?

Hey Joe,

nice work :icon_tup:

Gauging interest type threads arent allowed, so I cleaned up the thread a bit for you to keep it within the scope of club rules. If you'd like to sell these, the GB cost is a $75 one-time fee for a three month GB. Pretty reasonable price IMO.

You aren't allowed to ask if anyone would be interested in something?

No offense, but paying $75 just to find out if people are interested in purchasing something is a horrible rule.

I agree. That's rediculous. :icon_tdow

Ps very nice work. :)

Yeah, I'll throw in my two cents and say I don't like it either. I wanted to try and organize a group buy, but I haven't heard back from the vendor and don't think they would want to pay $75 without knowing how many people are interested.

But, rules are rules, eh?

it should also aid in cooling by keeping airflow thru the rad. and from the bottom you wont get so much turbulence disturbing that airflow,regardless, if this makes it to group buy,id like to see a price point,those stock pieces are hard to find,dont look near as effective,and are usually beat to hell if you do locate one,for the record im not interested:lol:

I had one but my shop teacher mistaked it for scrap and off to the yard it went before I even knew it was gone :( I can't blame him though, it wa sitting in a cabinet while I was working on my old sport to get it running the first time.

BTW, very interested in having another one.

Nce i really like it how about cooling panel by the rad i am in the mkt for one........interested

nice.. interested

glad to see there is gonna be some interest i have military drill this weekend so if i get a chance i will contact GoodfellaFD3S to get the ball rolling on a group buy

i talked with the powercoat company we use today and the finish on them will be more then likely be flat black powercoat

this is the exact pic i used to get an idea of what i was doin....
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=IMG_20111005_171123.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/IMG_20111005_171123.jpg" border="0" alt="Photobucket"></a>


its funny you ask......
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo01041412_1.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo01041412_1.jpg" border="0" alt="Photobucket"></a>
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&amp;current=Photo01111607.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo01111607.jpg" border="0" alt="Photobucket"></a>

--Joe

I'm interested in both. Any chance of a reproduction of the main undertray as well? Mine is rather beat up.

Are there clearance issues with verts? I seem to remember their being different bracing for verts and have only ever owned verts so I have nothing to compare it to.

If they will bolt on to verts and pending price, I would be interested.

thats nice, i got spare sheet metal but i could never get the cuts or folds that clean. I'd be down to purchase one if I wasnt unemployed =(