S4 sport undertray (yes i actually made one)
#1
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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&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&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&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&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&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&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&current=Photo02021659.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021659.jpg" border="0" alt="Photobucket"></a>
--JOE
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&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&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&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&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&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&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&current=Photo02021659.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo02021659.jpg" border="0" alt="Photobucket"></a>
--JOE
Last edited by GoodfellaFD3S; 02-02-12 at 10:18 PM.
#3
Rabbit hole specialist
iTrader: (11)
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.
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.
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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
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#12
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#14
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nice work
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.
#15
Rotary Enthusiast
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.
No offense, but paying $75 just to find out if people are interested in purchasing something is a horrible rule.
#17
Rabbit hole specialist
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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?
But, rules are rules, eh?
#18
tigers LOVE pepper!!!!!
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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
#19
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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.
BTW, very interested in having another one.
Last edited by REAmemiya_fan; 02-03-12 at 09:36 AM.
#22
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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&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&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&current=Photo01111607.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo01111607.jpg" border="0" alt="Photobucket"></a>
--Joe
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&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>
<a href="http://s198.photobucket.com/albums/aa216/fast87t2/?action=view&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&current=Photo01111607.jpg" target="_blank"><img src="http://i198.photobucket.com/albums/aa216/fast87t2/Photo01111607.jpg" border="0" alt="Photobucket"></a>
--Joe