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-   -   My crash bar/splitter creation/installation (kind of a how-to) (http://www.focusfanatics.com/forum/showthread.php?t=250631)

mikealicious 02-13-2011 05:23 PM

My crash bar/splitter creation/installation (kind of a how-to)
 
So I've had a tow hook on my svtf for awhile now, and up until yesterday, it's been basically purely aesthetics. It was weldled to the factory bumper beam, and would flex if you put any weight on it. So I decided (with some help of a friend) to make sort of a 'crash bar' that would be attached to the frame of the car, and re-weld the tow hook to that. I've also been wanting to create a splitter for a long time, so we decided to tackle both of those in one day. I tried to take pictures along the way to show you guys how we made them in case anyone else was wanting to do the same. Not sure if this qualifies as a how-to or not. lol

but here ya go:

first off, a picture of the car with the bumper and everything in the front of the car off

http://img406.imageshack.us/img406/8200/sam0732.jpg

we decided as part of this crash bar, we would re-make the radiator support as well. we did this because we wanted to be able to remove the crash bar/splitter if needed to. so we used the two bolts on either side of the car that the radiator support were using (red circles), for our bolts/holes for the crash bar.

http://img130.imageshack.us/img130/3246/sam0736.jpg

next we took a thin piece of aluminum to use as a template as we created the bends needed to use those holes and have a mounting part for the support beam

http://img16.imageshack.us/img16/1360/sam0738q.jpg

after we got that how we wanted, we got used the same steel that we used for my tow hook 1/8" (I think) thick, and 3" wide.

http://img684.imageshack.us/img684/5558/sam0739n.jpg

this stuff does NOT bend easy. so after cutting it to length, we created a couple of relief slits to help us bend it.

http://img87.imageshack.us/img87/6234/sam0743y.jpg

http://img29.imageshack.us/img29/4855/sam0742.jpg

once we applied a ton of heat and muscle to this stubborn piece of steel, we used the template to make sure the bends were accurate, then welded the relief slits for strength, and test fitted it on the car.

http://img826.imageshack.us/img826/3267/sam0746r.jpg

http://img97.imageshack.us/img97/1456/sam0748t.jpg

http://img200.imageshack.us/img200/6461/sam0753.jpg

http://img202.imageshack.us/img202/3737/sam0755j.jpg

next we took a 1"x2" piece of square steel tubing, cut it to length, and test welded it to the pieces we just made

http://img828.imageshack.us/img828/9206/sam0759.jpg

http://img20.imageshack.us/img20/6279/sam0760w.jpg

http://img163.imageshack.us/img163/6634/sam0762f.jpg

after that, we made little "beams" that would connect that piece to the new radiator support. you can see the radiator support on the top part of this picture. The two square holes we cut were for the rubber bushings on the bottom of the radiator. what you can't see in the pictures were the welded nuts on one end of those beams that would be used to bolt the bottom of the radiator support to those new beams.

http://img513.imageshack.us/img513/9228/sam0763.jpg

here it is test fitted to the car. (don't mind the calipers hanging in the background. we were painting those as well. multi-tasking ftw! lol)

http://img265.imageshack.us/img265/801/sam0766r.jpg

http://img38.imageshack.us/img38/7980/sam0767.jpg

after that looked good, we ground the welds for my tow hook, and re-welded it to the new crash bar, test fitted it on the car, and then painted everything.


http://img146.imageshack.us/img146/7470/sam0772l.jpg

http://img202.imageshack.us/img202/4440/sam0775j.jpg

http://img825.imageshack.us/img825/1125/sam0776.jpg



http://img690.imageshack.us/img690/8415/sam0781v.jpg

while the paint was drying for the crash bar, it was time to tackle the splitter. we laid my bumper on some cardboard, and created a design with it. once the design was created, we took the cardboard over to the car, and traced out what would need to be cut for header clearance as well as wheel clearance. once that was done, we placed the carboard template on the alumalite material, and used spray paint as a fast and easy way to trace it. we cut the template out, and took a hand held belt sander to smooth the edges. once everything looked good, we peeled back the protective film, prepped the material and painted it flat black

http://img148.imageshack.us/img148/9506/sam0733x.jpg

please ignore the fact that the cutout for the headers looks like a big penis [rofl]

http://img511.imageshack.us/img511/3681/sam0783.jpg

http://img690.imageshack.us/img690/2244/sam0784t.jpg

http://img638.imageshack.us/img638/3995/sam0786p.jpg

http://img338.imageshack.us/img338/5571/sam0792q.jpg

while the splitter was drying, we attached the crash bar/new radiator support to the car. no idea why it looks like it's still rusted in the pictures. doesn't look like that at all in person. think it was the lighting or something.


http://img828.imageshack.us/img828/2564/sam0787.jpg

http://img545.imageshack.us/img545/74/sam0788.jpg

http://img820.imageshack.us/img820/4400/sam0789.jpg

http://img211.imageshack.us/img211/3310/sam0790.jpg

we attached an "L" (or elbow) bracket to the radiator support. this is what the front part of the splitter would be attached to. we used a rivet gun and put 5 rivets in that bracket, and 2 in the k member (to attach the rear part of the splitter). We clamped the splitter up to the car and drilled the holes for the bolts.


http://img109.imageshack.us/img109/7292/sam0795.jpg

http://img710.imageshack.us/img710/3225/sam0796.jpg

http://img222.imageshack.us/img222/2728/sam0797.jpg

you can see the rivet on the k member

http://img529.imageshack.us/img529/671/sam0798.jpg

the splitter clamped to the car

http://img407.imageshack.us/img407/8183/sam0793p.jpg

the splitter with the mounting holes drilled in it

http://img831.imageshack.us/img831/843/sam0799p.jpg

installed the splitter to the car, and did some final checking/measuring before we put the bumper on.


http://img220.imageshack.us/img220/2268/sam0800.jpg

http://img249.imageshack.us/img249/5607/sam0801w.jpg

http://img51.imageshack.us/img51/598/sam0802h.jpg

http://img6.imageshack.us/img6/8853/sam0803z.jpg

put the bumper back on, as well as the headlights and everything else. then isntalled the support beams, took a few steps back, and was loving it.

the final product (please ignore how dirty the car is. new pictures of a much cleaner car will be taken soon lol)


http://img59.imageshack.us/img59/2781/img1622d.jpg

http://img411.imageshack.us/img411/2/img1624u.jpg

http://img262.imageshack.us/img262/3225/sam0814zb.jpg

http://img717.imageshack.us/img717/5007/sam0816e.jpg

http://img407.imageshack.us/img407/1603/sam0818y.jpg

http://img84.imageshack.us/img84/383/sam0821d.jpg

http://img199.imageshack.us/img199/574/sam0832m.jpg

http://img703.imageshack.us/img703/1415/sam0834.jpg

http://img526.imageshack.us/img526/6407/sam0836i.jpg

http://img255.imageshack.us/img255/3986/sam0838g.jpg

http://img708.imageshack.us/img708/7563/sam0841s.jpg


I'm open to any questions/comments/constructive criticism.

Let me know what you guys think! [cheers]

zx360 02-13-2011 05:55 PM

it turned out great mike! nice work to the both of you

mikealicious 02-13-2011 06:00 PM

Thanks Josh! Just trying to make the car perform better and a little more visually appealing. [:D]

Jetta555 02-13-2011 07:34 PM

looks dam good man nice job on the fabrication neat idea

Djzx3 02-13-2011 07:47 PM

Wow really nice looking, I always wondered how to do that type of lower splash/wind deflector? How is it mounted to the car, and is it piloting so that it's adjustable by those rods?

FuhFuh Focus 02-13-2011 07:49 PM

That looks pretty cool, looks like yall did a good job too.

2003SilverSVT 02-13-2011 07:51 PM

Very nice job !!!

Nickgt40 02-13-2011 07:57 PM

I am so envious of your lift.

Car looks great!

sleepyboy 02-13-2011 08:04 PM

Wow nice work!

mikealicious 02-13-2011 08:12 PM

Quote:

Originally Posted by Jetta555 (Post 3556065)
looks dam good man nice job on the fabrication neat idea

thanks man! I'll have to give credit where credit is due tho. A LOT of the fabrication work on this one was done by my buddy. Dude does awesome work and is always thinking outside the box. The fab idea I had in my mind had to do with removing the factory bumper beam. He wanted to do it without removing that. And we did.

Quote:

Originally Posted by djzx3 (Post 3556078)
Wow really nice looking, I always wondered how to do that type of lower splash/wind deflector? How is it mounted to the car, and is it piloting so that it's adjustable by those rods?

Not really sure your first two questions on this one. The wind deflector and how is it mounted to the car? It's an aerodynamic splitter. The way it works is it's smooth surface allows the air/wind to move quicker underneath the car. This creates less air pressure underneath the car and greater air pressure above the car (aka downforce). at higher speeds, it pushes the car down, giving it more traction under high speed cornering. I've road raced the car a couple of times last year, and plan to race it a lot more this year. One of the reasons I made it. Plus, I think it looks sick. ahah

but to answer your second question, yes. it is adjustable. Those rods screw/unscrew into themselves, so I can raise or lower the front of the splitter which would change the angle (change the downforce) of it.

Quote:

Originally Posted by FuhFuh Focus (Post 3556080)
That looks pretty cool, looks like yall did a good job too.

thanks man! It came out better than I thought it would. Fully functional and looks dope!

Quote:

Originally Posted by 2003SilverSVT (Post 3556084)
Very nice job !!!

thanks!

Quote:

Originally Posted by Nickgt40 (Post 3556088)
I am so envious of your lift.

Car looks great!

lol that's my buddy's lift. He's basically the "go-to" guy for virtually anything around our area. He does awesome work and does it super fast. That lift makes everything sooooo much easier. lol

Quote:

Originally Posted by sleepyboy (Post 3556094)
Wow nice work!

Thanks dude!


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