Would Like to Build Some Aero

[Sid_RallyX_82]

I would like to build a WRC style wing and defuser for my rally car. What aerodynamics have been developed in the community? Home brew or otherwise.
Examples:
Škoda_Fabia_WRC_Cyprus_Rally_2005.jpg
9.jpg
3654_KrisMeeke-Germany-2014_002_592x333.jpg
2013-frs-brz-ft86speedfactory-diffuser-2.jpg
Not sure what materials; Steel, aluminum, fiberglass, fibercarbon, kevlar... Looking into vacuum molding. May or may not use strakes. Also looking to making an under tray.
Any advice for the front end?

[Doug Brown]

From watching the rally videos on the web - especially when they go upside down, rollover, crash - the front under tray seems to be made of relatively thick (.125" or 3/16") aluminum. This gives protection to the oil pan / transmission as well as some aerodynamics to the undercarriage plus it is fairly lightweight and easy to fabricate.

[w4rkry]

I have see one Festy somewhere on here with some Plexiglass aero work before. Clif Dodd's AutoX car has some PVC sheet splitter and large duck spoiler that look pretty sharp.
I think Aero will be the next focus point in Festiva mods now that we have some very stable development in the Engine, Suspension, and Brake side of things.

I look forward to what you and others can come up with!

[w4rkry]

Found the Pictures I was thinking of, from the Road Racing Thread.

Pictures
Neil (gorgenheim)

[likeJIF]

I made that diffuser, I assisted in making the front splitter we used and the wing came from a guy that Neil knows. Keep in mind all this was done for a 24 hrs of Lemons car and not on a daily car.

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[likeJIF]

This is the front splitter, sheet metal and an F150 front air dam upside down.

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[likeJIF]

Put side skirts on the race car, from a Dodge Daytona R/T truck.

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[Sid_RallyX_82]

Will look into plexiglass. Good idea
Video: Kyle Engineering: CF vs FG vs K
Thoughts on combining FG with a cover layer of Kevlar for rally diffuser? I think that might be a good compromise of strength, stiffness, impact/abrasive resistance
He mentioned possibly doing a video on different resins/epoxys, but I haven't found it yet

[Sid_RallyX_82]

Also, who out there with 3D printers can tell us what's the largest thing we can have someone print at low cost?
Kyle Engineering: OnShape CAD

[ryanprins13]

All depends on how many pieces you want to glue togeather. Longest piece we can make is 24in iirc but none of our machines make cheap parts

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[Sid_RallyX_82]

All depends on how many pieces you want to glue togeather. Longest piece we can make is 24in iirc but none of our machines make cheap parts

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How does the glue compare in strength and rigidity with the printed material?

[Sid_RallyX_82]

Not practical for my application, but I thought this was neat
Kyle Engineers; Infinity Wing

[likeJIF]

Sid are you on the FB forum page? I have many ideas that I have done and played with that may help with what you are planning on doing.

[likeJIF]

Sid, whatever came of this? Did you ever come up with anything? I never received any messages on the FB page or messages here.

[Sid_RallyX_82]

Sorry for the late reply. Yes, I'm on the FB page, the name's Jared Bennett. I'm playing with some ideas in OnShape cad; look up JB_FF-Wing and JB_FF-Front-Lip. Still looking for a free simulator and I have a few very large projects to finish before I start this; might be a year or two, but to be optimistic that just means more time for refinement