Z4M Custom Aero Package - Build Journal update #7

[inTgr8r]

Things have been moving along (slowly) with the design and fabrication of my custom aero package.
I figured it was about time that I post an update on what I've been up to.

I'll keep this thread as an ongoing blog with updates and for your feedback.
I'll post links here in this first post to jump to the updates.


UPDATE LINKS
1. Design ideas and development of the from bumper aero
2. Front bumper pieces dry fitted in place
3. f/g Layups
4. Front Mounted and ready for track
5. Prototype in action at the track
6. Design revision 1
7. Materials change and testing for GB production.

[inTgr8r]

Update #1

Background
As many of you know I have had an aero package on the car already, which served as test bed.
Previously I have had;
- APR front splitter
- side extensions that I made up from the same material as the ARP front
- rear diffuser
- VRS hyper narrow rear wing, which is the only piece still remaining.

This is the aero at that time




Overall objective
From running the original aero package at the track I found that the front splitter and the rear wing were easily the most noticeably functional pieces.

My goal was to enhance these 2 pieces further while creating a more integrated GT type package.
For the other pieces, while less functional, I want to make something that looked great and helped pull everything together.

I'm no automotive designer or aero engineer with a wind tunnel, so I used what I learned with the APR etc parts and design elements that I liked on other cars (e.g. GT3) to come up with my design.

Materials
I was looking for something that was relatively easy for me to work with and leaned on some old RC model building experience.

My core pieces are Balsa wood.
Balsa is extremely light weight, not much different from foam board.
It is easy to laminate and form into complex, compound curves.

When final core shape is achieved, it is epoxy resin infused and fiberglassed.
This stage turns the Balsa from a very soft wood into a solid rock hard piece that is very structurally sound.

It can then be finished and painted in a normal manner.

OK... onto stage 1 the front aero bumper
This is easily the most complicated piece to the whole aero kit.
There are MANY different compound curves and arcs on multiple planes.

I'm making the front in three pieces as its far too complicated to do as a single piece.
The fang cover (yes its gone) & wheel arch extension (x2) and the center section.

In developing the front, I wanted to add more downforce than I was getting with the APR.
I also wanted to clean up the aero around the leading edge of the front tires due to the large undercut of the bumper in front of the tires.

Stage 1 pics
the center section clamped after lamination of the top layer


after the glue dried and before any shaping


the fang cover/side extensions
This is a good example of how complex the shape is.
The tool on the bench beside the piece is a profile gauge used to match the shape from one piece to another.


and a few different angle shots with the pieces loosely in place.
Note the center section is still in rough form and has not been fully matched. Its sitting about a 1/4" low at this point.
The gaps between pieces are purposly large at this point to provide space for f/g.
The sides are about 95% and just need some final tweaking before they are resin infused and fiber-glassed.












All feedback on the design is welcomed.

.

[longress]

Outstanding job!

[MZHammer]

Wow.

[Steeler]

Very impressive Ian.
Can't wait to see the F/G lay up.

[Daemonblitz]

Saw this in person already, it looks spectacular. Can't wait to see it with a coat of paint once it's finished.
Keep it up !

[inTgr8r]

Originally Posted by longress

Outstanding job!

Originally Posted by MZHammer

Wow.

Originally Posted by dbarton62

Very impressive Ian.
Can't wait to see the F/G lay up.

Thanks guys, its been a ton of fun so far.
I'm taking my time with it to let the design ideas ferment a little.
I've made a few tweaks as Ive gone along.

[Vanne]

Wow, just WOW!! that is AWESOME work!!

[inTgr8r]

Originally Posted by Daemonblitz

Saw this in person already, it looks spectacular. Can't wait to see it with a coat of paint once it's finished.
Keep it up !

Thanks, I appreciated your input the other day.

Cant wait for paint either.
I'm still struggling whether to go body color or black; leaning a little more towards black atm.

[inTgr8r]

Originally Posted by Vanne

Wow, just WOW!! that is AWESOME work!!

hey Vanne thanks.
I'm sure you can relate to building balsa boards.
Techniques are similar except for the resin & f/g used; I think they normally use a UV cure?.

[abashoe]

please take my money and start selling them!

[Vanne]

Originally Posted by inTgr8r

hey Vanne thanks.
I'm sure you can relate to building balsa boards.
Techniques are similar except for the resin & f/g used; I think they normally use a UV cure?.

yep, UV cure, over a week or 2.. Used to use Balsa all the time. love working with it, so strong, so light.. brilliant idea and materials for the aero package mate.

Will be standing by with much interest on how you develop this.

[inTgr8r]

Originally Posted by abashoe

please take my money and start selling them!

I'm making templates of everything as I go to make reproduction easier.

[No_Dominion]

Looks awesome, looking forward to further developments.

I'll likely jump on the side extensions as well as rear diffuser if both of those end up making it to the production phase.

That wing is sick, btw... I never thought I'd see one that I'd considering putting on my car, but damn, that just looks awesome. Where did you source the wing? And did it require a custom bracket?

[inTgr8r]

Originally Posted by No_Dominion

Looks awesome, looking forward to further developments.

I'll likely jump on the side extensions as well as rear diffuser if both of those end up making it to the production phase.

That wing is sick, btw... I never thought I'd see one that I'd considering putting on my car, but damn, that just looks awesome. Where did you source the wing? And did it require a custom bracket?

Thanks!
The sides will be next, I'm working out details on a couple of designs.
I'm on the fence with both & will likely post a poll with mock-up samples.

I have the OE sills on my car, so they will obviously be the first done.
I will need someone local with aero side sills at some point for fitment.

re the wing, its a VRS (Varis) hyper-narrow.
It came c/w the mounting brackets.
IIRC, its no longer in production fro the Z4MC but I could be wrong.
You'd have to check with a Varis dealer (Evasive, Bullet proof, Vivid etc)
If available, also check if they have changed it at all, I"ve seen it on a BRZ and it looked like the mount attachment points were moved further inboard.

[No_Dominion]

Better to take the time and make sure you're happy with the design in the long run than rush it. Also, I'm glad you're going to be making a version for each side skirt style, that's going to make a big difference as far as looking proper. I'd gladly offer my car as a test vehicle, but I don't live anywhere nearby, to say the least.

Hopefully they do still make the wing, or maybe there are a few still floating around out there. I'll let you know what I find out

[ZMCoupe]

Fantastic work! The pieces look so good and well thought out. I look forward to watching this progress and as abashoe said take my money!!!

Great job

[Shutterspeed]

Props on undertaking this project, can't wait to see more results. What you have so far looks great and I'm sure it'll function marvelously.

[torchmedia]

TAKE MY MONEY NOW

Seriously.

[inTgr8r]

Thanks guys

[3GFX]

Looked great in person, fitment and design were nice.

Keep it up...can't wait to see the next phase.

[v3.2mc]

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