Tuesday, March 6, 2012

Lexan rear window, DIY front crossmember, and the pinaccle of go-faster bits: the spoiler

Lexan is fantastic. Its unbreakable for a kickoff, but its also extremely light and cheaper than dirt... Seriously, its actually cheaper to buy a sheet of lexan than some potting soil, also they are both sold at home depot.

Step 1: Take heavy glass out of insanely tacky german window goop



Step 2: Make template of original window from cardboard so german window goop doesnt get all over the new lexan






Step 3: Trace then cut



Test fit



Step 4: make some supports from angle aluminum or something similar



The steel used for the hatch was too flimsy for my taste, so some 1/4" steel plate left over from the roll cage was used to make a mounting plate for the wing





Step 5: test fit again, then prepare to drill more consecutive holes than you ever have before....and yes, thats what she said



Step 6: Lay down some RTV or black weatherproof sealant before permanently attaching the lexan, it will help keep the lexan in place as well as keep water out of your hatch.



Step 7: Rivet until your wrist is completely destroyed







Drill holes in mounting plate and mount spoiler using heavy duty home depot supports for the back part of the uprights.



I ended up putting a small lip where the gap between the end of the lexan and back of the hatch with some thick tab aluminum and added a small lip which (in theory) should help to produce more down force.







Sidebar: DIY crossmember... If you have more than 500hp in any car, its a good idea to reinforce the front of the car, even with a chassis as Viagra stiff as the 928's

Materials= square steel tube, tab steel

Step 1: Drill 2 holes in tab steel



Step 2: bolt on to lower control arm then place square steel tube on top



Step 3: Weld it up then add paint:




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