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The project is still going - just slower than anticipated.
The current setup is pure carbon and kevlar reinforced plastic.
Dimensions were roughly 40 by 42 (the 42" section covering the rear subframe), however upon mocking up the install, I decided it wasnt wide enough, so Im increasing the width to 52" with additional fences.
I have a permanent mold made of fiberglass, so I can make as many main sections and fences as I want (this also conveniently makes the thing universal).
At this point I just have to get the new fences bolted in and the refinish the surfaces.
Also I plan on making a gurney flap along the upper trailing edge of the diffuser to add stability to the unit.
Mounting brackets are planned on being carbon. I already have the brackets partially done - just have to remove them from the one time foam molds and refinish them.
After the diffuser is finished and mounted Im planning on removing the front valence to eliminate the high pressure zone it creates and then making a front undertray as well as tunneled front fender liners (one piece carbon - the brake ducting will come from the radiator area) but without a splitter in order to keep the aero drag as low as possible. Additionally, I plan on modding the hood with vents made of fiberglass, and then eventually making a full pin on carbon hood from that...
The biggest stall is money and time as I have been busy redoing my 60 year old house so the car stuff has had to take a backseat over the last few months...
Thanks for the interest!
EDIT:
Forgot to mention - I modified the muffler section with thrush units (rebranded flowmasters) that I tucked in higher with 4" single tips - this allows much more room for the diffuser. Below are pictures of the diffuser before I decided to widen it:
This project seems neverending! New carbon fiber brackets are in the works, as I didnt like the design of the first set. Here are a few updated images I took a couple weeks ago after adding a gurney flap to help stiffen the part up:
Ive got a permanent mold for the main diffuser body parts so they can be copied indefinitely. The mounts and gurney flap were done with lost mold processes but wouldnt be hard to replicate either
After all the aero parts get mounted (the front undertray and diffuser along with some proper hood ventilation), Ill do some high speed testing this spring (hopefully it will be done by then) to see how the changes affect the vehicle.
Front undertray in a rough, straight from the mold finish:
EDIT: Explanation for the undertray
The undertray removes the center valence and uses a splitterlike shape to help force air to the cooling system, then covers the front subframe terminating around where the oil change items (plug and filter) are exposed.
The front of the base c6 bumper has a foil shape that could work as a diffuser, however the valence creates such a turbulent and high pressure area that it would create lift as well as impede the function of said foil shape in creating any form of downforce
The purpose of the valence is to prevent air from spilling under the car from the front while lowering the coefficient of drag and lowering rear end lift. The downside is front end lift. By flattening out the underside of the car while removing parts such as the front valence, the car can start to reduce overall lift and potentially create downforce - especially if the rear half of the vehicle's underside is going to get covered as well (as in the case of the diffuser)
I have done a lot of wind tunnel work and racing. I can tell you winning teams must use both. I have seen things work in the wind tunnel and much better on track. I have also seen things work great in the wind tunnel and be a complete flop on the track. But, most of the time, wind tunnel testing gives a reasonable prediction of what will happen on the track. Just my 1 cent!
Ive got a permanent mold for the main diffuser body parts so they can be copied indefinitely. The mounts and gurney flap were done with lost mold processes but wouldnt be hard to replicate either
After all the aero parts get mounted (the front undertray and diffuser along with some proper hood ventilation), Ill do some high speed testing this spring (hopefully it will be done by then) to see how the changes affect the vehicle.
Front undertray in a rough, straight from the mold finish:
EDIT: Explanation for the undertray
The undertray removes the center valence and uses a splitterlike shape to help force air to the cooling system, then covers the front subframe terminating around where the oil change items (plug and filter) are exposed.
The front of the base c6 bumper has a foil shape that could work as a diffuser, however the valence creates such a turbulent and high pressure area that it would create lift as well as impede the function of said foil shape in creating any form of downforce
The purpose of the valence is to prevent air from spilling under the car from the front while lowering the coefficient of drag and lowering rear end lift. The downside is front end lift. By flattening out the underside of the car while removing parts such as the front valence, the car can start to reduce overall lift and potentially create downforce - especially if the rear half of the vehicle's underside is going to get covered as well (as in the case of the diffuser)
3 layers of 6oz twill carbon... I was hesitant about the strength, but the design made it stiff enough. With that part I used male and female molds and compressed the crap out of it after squeegeeing out as much excess epoxy as possible. It turned out so light that I can pick it up with my pinky.
Now if the weather would cooperate I could get the darned thing installed!
3 layers of 6oz twill carbon... I was hesitant about the strength, but the design made it stiff enough. With that part I used male and female molds and compressed the crap out of it after squeegeeing out as much excess epoxy as possible. It turned out so light that I can pick it up with my pinky.
Now if the weather would cooperate I could get the darned thing installed!
09-02-2014, 12:45 PM
