Time for some aero (and an update)!
For the front aero, I wanted to go with a custom setup that gives me a large front splitter and dive planes to match up to a large rear wing. For now, I decided to mock up a working prototype using wood for the splitter and thin wall steel square tubing for the splitter frame. By my calculations, using thicker wall aluminum would’ve only saved 3 or 4 pounds. Future plans are to make a carbon fiber over foam splitter and either Swiss cheese the steel square tubing or replicate the frame in aluminum.
Earlier in the build, I welded on some down “C” channel with captive M6 nuts onto the front clip. So now I just needed to make a splitter frame that will bolt up into place…easy peasy…
I want the splitter to extend forward 6” and ride 2 ¾” off the deck. Total width is 70". To ensure rigidity, I chose to run square tubing bars forward to give support rather than using support cables. Just gives it a cleaner look , IMO. Of course, the tough part was making sure the frame was level fore aft and side to side. By making this frame, the splitter can be a simple sheet of plywood or carbon fiber (or alumilite or ABS…).
To mount the splitter, I welded in captive M5 nuts inside the square tubing and capped them with a 45 degree cut for a nicer look. I used countersunk fasteners for a clean underside. The back of the splitter is held in place with “L” brackets. This means only fasteners are used at the front so I don’t have to reach back in there to secure the rear of the splitter.
M5 nuts welded in square tubing.
Sizing up a sheet of plywood. Shovel nose splitter?
Mocking up splitter, fence and dive plane box.
Steel frame mounted to splitter. Note tabs on backside with captive nuts for the aluminum second panel.
Splitter and frame in position on the floor. Zero clearance splitter?
Underside of splitter.
I also chose to make the splitter rather short to make removal for loading easier (though in the end I made multi-section ramps so I don’t have to remove it). The idea being that I will make a separate panel to go behind the splitter. So the splitter goes back to the front of the wheel wells and an aluminum panel that is 32” x 32” extends the flat bottom past the wheel wells. Eventually the plan is to flat panel the entire underside into a diffuser.
To keep the plywood splitter from disintegrating in the wet, I painted and varnished it. This sheet is 15/32” cabinet grade ply. I also floated the underside of the panel with flexible spackle to give a smooth-as-glass finish. So far after several rainy sessions, it’s showing no signs of water intrusion. But I know it’s just a matter of time.
