Bought cardboard to make a rough design of rear diffuser.
Sheet was bout 20”x28” and had to use about 2 & 1/2 sheet to cover the whole rear bumper. Had to make sure I have space for exhaust to come out.
I don’t want to make it too low to the ground, so I made sure to get it up much as I can. Which means, I had to cut out between 2 fins.
Now to secure the diffuser, I looked at few of other brands installation to see how they’re mounting them. Front, I’m thinking of using lower bolt of sway bar mount.
Side, I’ll prob need to put some few rivets and Mount w the plastics. Rear, there were few options. Verus was mounting to the bracket where fins are connected and have extension bracket to connect the diffuser. Driveway Lab is just mounting to the fins. I’m pretty sure it’ll work fine, but I don’t want to put too much stress on the bumper, so I’m planning to make a long bracket to connect directly to the chassis. There are 2 screw holes where it used to mount heat shield. I’ll be using that to connect the brackets.
As for the metal I’m using to make the rear diffuser, I’ll be using 0.63 thickness aluminum (5052-H32). Noticed that most brands are using that thickness plus quality of aluminum, so I assumed that’ll be the best thickness to go with.