Drambeenie Risers MEGATHREAD.

[Drambeenie]

Originally Posted by tehShirt

@Drambeenie Any update to this?

Hey sorry for the non-updates! Things got a bit busy work wise the past couple weeks, but we're still moving forward with the project.

We're currently working with the 3D model in CAD to establish the right shape. The scan we got was basically a solid and we're working to "vectorize" it. Going to start moving quick again now that things have settled down elsewhere.

[Drambeenie]

Quick update. Based on the complexity of the inner and outer structure and the work that would be required, we're going to create one piece that incorporates the shell and the structural piece. This will be easier to make, print and sell if I decide to go that route. It will also be printed in a very strong plastic. If we decide to sell the piece, we'll need to perform an SEA - which tests the structural integrity of the part.

I'm taking more accurate measurements tonight for the 3D modeling process to incorporate the structure - Modeling will start sometime next week.

[Drambeenie]

Started CAD design for the new shape. The model looks much larger than it actually is. At scale it's exactly 2x the height of the current piece, which is going to look great on the car.

Unlike a traditional spoiler, these pylons don't sit ontop of the trunk. They actually sit on a tilted and sloping angle on the trunk. So, while it looks like this is a 1 foot high spoiler, it's actually only about 12cm high.

Let me know if you have any questions or thoughts!

[Fd3sr2]

very interested, particularly about the gurney flap idea. if you are possible producing risers, end plates, and a gurney flap- has there been any thought to a
different proportion element?

[Drambeenie]

Originally Posted by Fd3sr2

very interested, particularly about the gurney flap idea. if you are possible producing risers, end plates, and a gurney flap- has there been any thought to a
different proportion element?

So given the amount of work this requires (a lot more than I thought!) I'm going start with the higher risers first. Depending on how that looks (say it doesn't look proportional) we'll address it then.

We also have to look at the project as a whole. If I decide to sell this and am able to re-coupe my investment, I'll gather interest to see if bigger end plates or a gurney flap is the next direction.

I think a combination of all three will look amazing, the only limitation is that doing a 3D scan of the spoiler, as it's quite a large piece to scan, costs a lot of money.

[spike021]

Awesome progress Drambeenie! Can't wait to see a prototype

[Gunman]

Red is the scan data, and yellow the new surface? Good CAD geek porn!

[Drambeenie]

Originally Posted by Gunman

Red is the scan data, and yellow the new surface? Good CAD geek porn!

Yep!

Even more goodies coming through... Here's a cut away model that currently contains no inner structure - That will be worked on tomorrow.

[Drambeenie]

We're currently looking into sourcing the metal pieces for the part.

Option A: The bolt cut out will include the bolt head plus the size of a washer. The reason for this is so that we can epoxy the bolt head into the piece, then let that dry. Then we'll epoxy the washer to the part holding in the bolt head - This way we have a strong lock against the part. The epoxy can handle 3000PSI of force. We'll test it and see how it holds up on the prototype part






Option B: Use an elevator bolt that has a very wide head for increased surface area contact.





Option C: Knurled head screw. This will have a very high surface area contact between the epoxy and the piece.





I'm personally leaning to Option A as we get a two way lock. We'll see.

The threads at the top of the part to secure the wing into the riser will be:

[x808drifter]

Best option would be A:
And make the hole for the head hexagonal also.
Extra protection against stripping from over tightening. (nothing worse than a bolt that just spins)

The only way I see better retention against the bolt pulling out would be to fiberglass over the washer in A:.

[Drambeenie]

Originally Posted by x808drifter

Best option would be A:
And make the hole for the head hexagonal also.
Extra protection against stripping from over tightening. (nothing worse than a bolt that just spins)

The only way I see better retention against the bolt pulling out would be to fiberglass over the washer in A:.

Appreciate the feedback. We've decided on Option A and have ordered the metal hardware.

We'll see how well the part holds up with this two part locking. I was thinking about the additional fiberglass on the bottom. The epoxy we're going to use is marine epoxy used on boats, so we think it'll be plenty strong, but if not we can see other ways to reinforce.

The riser and wing should actually be taking a lot of downward force (ie downforce) onto it rather than being pulled apart - So giving it some more thought Option A might be all that's necessary to secure it in place.

After we test fit the prototype and print the production version of the piece, we'll do plenty of testing to make sure it doesn't fly off and decapitate anyone.

[x808drifter]

Originally Posted by Drambeenie

Appreciate the feedback. We've decided on Option A and have ordered the metal hardware.

We'll see how well the part holds up with this two part locking. I was thinking about the additional fiberglass on the bottom. The epoxy we're going to use is marine epoxy used on boats, so we think it'll be plenty strong, but if not we can see other ways to reinforce.

The riser and wing should actually be taking a lot of downward force (ie downforce) onto it rather than being pulled apart - So giving it some more thought Option A might be all that's necessary to secure it in place.

After we test fit the prototype and print the production version of the piece, we'll do plenty of testing to make sure it doesn't fly off and decapitate anyone.

One time use DRS.

[Drambeenie]

Almost there!

We've added a crosshair design ontop to give it that polished look, and implemented Option A. In addition to the screw heads being epoxied and locked in with a washer, we added a little reservoir on the bolt head so an ever better mechanical lock with the epoxy.

The next step is getting the measurements for the green trunk clip that started this whole thread, adding it to the design (see weird metal angled piece) and then building the inner structure. Then we can get the prototype printed! Bolts/washers/inserts have already arrived.

[tehShirt]

Looks great, excited to see the printed part! Just curious, but could you possibly use the same setup on the bottom as top, with the threaded inserts and then use a threaded stud?