80-86 rear "S" Spoiler with wiper delete ?
12-29-2011, 02:22 PM
#17
Rennlist Member
Thread Starter
Thank you James & Ken, Just downloaded the "Project 928" pdf, and had a good look at the prototype rear center spoiler that's on pages 125 & 126. It looks great, and is close to what we had in mind. Roger, please place an order for (1) prototype rear spoiler 
T
T
Last edited by 77tony; 12-29-2011 at 02:52 PM.
12-29-2011, 02:40 PM
#18
Administrator - "Tyson"
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12-29-2011, 02:54 PM
#19
Inventor
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12-29-2011, 03:53 PM
#20
Rennlist Member
Then I had to wonder why some kind of patch couldn't simply be cut to fit and glued in to cover the hole flush with the spoiler. I think that is already suggested in this thread; and I don't think anyone really needs me to cut such a patch out of something for them.
On the other hand, the most professional way to do this for a large number of users would be to simply make a new spoiler center section without the recess for the wipers. I have to wonder what it should be made of and how it would be made to match the rest of the spoiler pieces. Perhaps that is a fiberglass project for someone.
Maybe the best solution is to fill the void with bondo, sand it out and paint it to match. That's probably what I would do in fact if I were doing this for myself. That does not sound very creative and it seems kind of crude, but that is probably exactly what the factory did for those very few cars with this delete.
Jerry Feather
12-29-2011, 03:57 PM
#21
Race Car
Really? Bondo dropped into a somewhat flexible surround? The thermal expansion must be vastly different? Seems like cracks around the edge of the fill would be a persistent issue?
There is an aftermarket variant out there, ebay and elsewhere. I have no info on it though in terms of composition, treatment of area where OEM is clearanced for wiper, etc.
Ducktailed sharks...whats wrong with you people?
There is an aftermarket variant out there, ebay and elsewhere. I have no info on it though in terms of composition, treatment of area where OEM is clearanced for wiper, etc.
Ducktailed sharks...whats wrong with you people?
12-29-2011, 04:10 PM
#22
Rennlist Member
Actually there is a product out there that would probably be just perfect for this rather than bondo. I can't remember the name of the company who makes it--something like alco alcon or similar--but it is a two part substance that when mixed and crued it is just like hard rubber, and black as black rubber also. The same company makes another product that I recall is named "Aluminun F-2." I have used both of these product in making molds for wax duplicates of projects to be cast in bronze or aluminum as in investment casting.
I'll bet that if one were to take some kind of mold of the surface of the spoiler next to the void, then clamp it over the recess in question, then mix up the two part rubber like compound and pour it into the holes where the wipers were, it would probably come out just about perfect when it cures.
Jerry Feather
I'll bet that if one were to take some kind of mold of the surface of the spoiler next to the void, then clamp it over the recess in question, then mix up the two part rubber like compound and pour it into the holes where the wipers were, it would probably come out just about perfect when it cures.
Jerry Feather
12-29-2011, 05:26 PM
#23
Rennlist Member
I had a few minutes at work to reseaerch the product I had in mind. It is by Devcon and is called Devcon80. It is referred to as casting rubber and is said to end up about as hard as the rubber on the heal of your shoe. It is said that there is an additive available that will let it end up softer. The product is apparently avialable from McMaster-Carr or Grainger.
Jerry Feather
Jerry Feather
12-29-2011, 06:25 PM
#26
Rennlist Member
Tony and Michael and the others who might be interested in the subject spoiler with the wiper delete, here is how I would do this modification:
Starting with the spoiler you want to fill, I would first carefully shape a piece of sheet aluminum so that it fits the contour of the top of the spoiler with the flare up in the rear and a sort of flange down along the front edge. It should fit fairly snuggly to the spoiler. Then I would thoroughly clean the area of the spoiler over to the side where the indent is not. Then I would wax the area where the indent is not very thououghly or cover it with any other release agent of you choice. Then I would sand the side of the sheet aluminum that I have formed to fit the spoiler so that the next agent will get a good mechanical bond to it.
The next agent is going to be any kind of epoxy cement, such as JB Weld that everyone seems so fond of. I would mix up enough of that to cover the area of the spoiler that is going to be under the aluminum form that I have made. Then cover the spoiler completely with the epoxy in the area that we are going to put the aluminum sheet and then put the aluminum sheet over it and clamp it down so as to get complete coverage of both the spoiler and the aluminum, hopefully without bubbles in it. Let it cure.
Then pull the aluminum off with the epoxy stuck to it which is now a copy/mold of both the shape of the top of the spoiler and of the texture of the surface of the spoiler. It is going to be your mold for the surface of the hole delete effort.
Now, clean the indent where the wipers were very carefully and even using very agressive sand paper down on the inside of the indent so as to get a good mechanical bond. Take the Devcon 80 product and mix it up, with or without the softening agent, and first with a small disposable brush paint the indent edges around the surface with the mixes Devcon 80 compound. You need to get just enough outside the indent so that you will have a good clean and hopefully continuous surface when you are done.
Then or before, put some kind of good release agent (wax) on the texture surface of your surface mold made first and then carefully clamp it into place over the wiper indent so that it is a tight fit to the spoiler. Now, turn the spoiler over so the wiper arm holes are upward and pour the indent completely full of the Devcon 80 two-part compound.
Now here is the trick to full or more nearly full, success to this project, since bubbles are going to be your enemy. You need to have determined ahead some method of lightly vibrating your work piece while the compound cures. The guy who taught me this process used his drill press by simply placing the subject on the press table and turning the motor on and letting it lightly vibrate until it was cured. That allowed the air bubbles that are inherent in the mixing process to vigrate upward and away from the surfaces to be molded. Something like that needs to be devised here. Put your workpiece in the vibration enviornment and let it cure.
When it cures you can take it apart and see what you have. You may find that there are some indications of the edges of the repair/modification, but probably none that cannot be cured perhaps with some trimming and a light application of the Devcon 80 compound on the surface to look it all into place.
Then, if the color doesn't match, I don't have a clue about what you might do about that. Well, maybe a clue, and that is that this Devcon Material is a Polyurathane product, so perhaps plastic or vinyl paint can make it all match.
I wish I had one of these to try this with, but all of my cars are S4, and when I delete the rear wipers I won't have this problem. In fact, I will even delete the spoiler entirely.
Jerry Feather
Starting with the spoiler you want to fill, I would first carefully shape a piece of sheet aluminum so that it fits the contour of the top of the spoiler with the flare up in the rear and a sort of flange down along the front edge. It should fit fairly snuggly to the spoiler. Then I would thoroughly clean the area of the spoiler over to the side where the indent is not. Then I would wax the area where the indent is not very thououghly or cover it with any other release agent of you choice. Then I would sand the side of the sheet aluminum that I have formed to fit the spoiler so that the next agent will get a good mechanical bond to it.
The next agent is going to be any kind of epoxy cement, such as JB Weld that everyone seems so fond of. I would mix up enough of that to cover the area of the spoiler that is going to be under the aluminum form that I have made. Then cover the spoiler completely with the epoxy in the area that we are going to put the aluminum sheet and then put the aluminum sheet over it and clamp it down so as to get complete coverage of both the spoiler and the aluminum, hopefully without bubbles in it. Let it cure.
Then pull the aluminum off with the epoxy stuck to it which is now a copy/mold of both the shape of the top of the spoiler and of the texture of the surface of the spoiler. It is going to be your mold for the surface of the hole delete effort.
Now, clean the indent where the wipers were very carefully and even using very agressive sand paper down on the inside of the indent so as to get a good mechanical bond. Take the Devcon 80 product and mix it up, with or without the softening agent, and first with a small disposable brush paint the indent edges around the surface with the mixes Devcon 80 compound. You need to get just enough outside the indent so that you will have a good clean and hopefully continuous surface when you are done.
Then or before, put some kind of good release agent (wax) on the texture surface of your surface mold made first and then carefully clamp it into place over the wiper indent so that it is a tight fit to the spoiler. Now, turn the spoiler over so the wiper arm holes are upward and pour the indent completely full of the Devcon 80 two-part compound.
Now here is the trick to full or more nearly full, success to this project, since bubbles are going to be your enemy. You need to have determined ahead some method of lightly vibrating your work piece while the compound cures. The guy who taught me this process used his drill press by simply placing the subject on the press table and turning the motor on and letting it lightly vibrate until it was cured. That allowed the air bubbles that are inherent in the mixing process to vigrate upward and away from the surfaces to be molded. Something like that needs to be devised here. Put your workpiece in the vibration enviornment and let it cure.
When it cures you can take it apart and see what you have. You may find that there are some indications of the edges of the repair/modification, but probably none that cannot be cured perhaps with some trimming and a light application of the Devcon 80 compound on the surface to look it all into place.
Then, if the color doesn't match, I don't have a clue about what you might do about that. Well, maybe a clue, and that is that this Devcon Material is a Polyurathane product, so perhaps plastic or vinyl paint can make it all match.
I wish I had one of these to try this with, but all of my cars are S4, and when I delete the rear wipers I won't have this problem. In fact, I will even delete the spoiler entirely.
Jerry Feather
12-29-2011, 07:28 PM
#27
Nordschleife Master
I got the ping. I'm just trying to figure out just what might be the best way to fill the void left when the wipers are removed. The thought I first had was that what was being asked about is simply a plastic insert that perhaps snaps into one or both of the wiper holes and then has a triangular upper shape that basically fills the hole flush with the rest of the spoiler. I think that would still leave a very prominent outline of the opening.
Then I had to wonder why some kind of patch couldn't simply be cut to fit and glued in to cover the hole flush with the spoiler. I think that is already suggested in this thread; and I don't think anyone really needs me to cut such a patch out of something for them.
On the other hand, the most professional way to do this for a large number of users would be to simply make a new spoiler center section without the recess for the wipers. I have to wonder what it should be made of and how it would be made to match the rest of the spoiler pieces. Perhaps that is a fiberglass project for someone.
Maybe the best solution is to fill the void with bondo, sand it out and paint it to match. That's probably what I would do in fact if I were doing this for myself. That does not sound very creative and it seems kind of crude, but that is probably exactly what the factory did for those very few cars with this delete.
Jerry Feather
Then I had to wonder why some kind of patch couldn't simply be cut to fit and glued in to cover the hole flush with the spoiler. I think that is already suggested in this thread; and I don't think anyone really needs me to cut such a patch out of something for them.
On the other hand, the most professional way to do this for a large number of users would be to simply make a new spoiler center section without the recess for the wipers. I have to wonder what it should be made of and how it would be made to match the rest of the spoiler pieces. Perhaps that is a fiberglass project for someone.
Maybe the best solution is to fill the void with bondo, sand it out and paint it to match. That's probably what I would do in fact if I were doing this for myself. That does not sound very creative and it seems kind of crude, but that is probably exactly what the factory did for those very few cars with this delete.
Jerry Feather
Bondo sounds like it would work. A plug made by a professional sounds better though.
12-29-2011, 07:40 PM
#29
Rennlist Member
Michael, I guess I see a big difference between having a plug that fills the hole and having the spoiler look like it never had the wipers in the first place. Some of the response that Tony has had to this thread suggests both approaches, particularly those looking for the original factory spoiler from the cars with the original wiper delete.
What exactly are you thinking would be the ideal solution to the after market delete. How do you envision a plug being configured?
Jerry Feather
What exactly are you thinking would be the ideal solution to the after market delete. How do you envision a plug being configured?
Jerry Feather
12-29-2011, 09:26 PM
#30
Race Car
I have never explored this..but it seems like somebody already has something semi-rigid intended to be painted: http://www.extremedimensions.com/11725.html
And if so, why the heck aren't they doing a OEMish front spoiler that almost all new owners have the pleasure of replacing, either because its damaged on purchase- or shortly after they assume custody..and aftermarket aero mirrors for heaven's sake.
Again, no affiliation and I haven't contacted them for details, but if enough folks think it is really such an interesting idea, perhaps they'd entertain a group-buy for a smoothly contoured wiperless version.
And if so, why the heck aren't they doing a OEMish front spoiler that almost all new owners have the pleasure of replacing, either because its damaged on purchase- or shortly after they assume custody..and aftermarket aero mirrors for heaven's sake.
Again, no affiliation and I haven't contacted them for details, but if enough folks think it is really such an interesting idea, perhaps they'd entertain a group-buy for a smoothly contoured wiperless version.