Belly Pan for a Mini Van. That's some serious acreage.

[orange4boy]

Well, I have finally started the daunting task of panning the van. I bought a sheet of 6mm coroplast for the job which is stiffer and thicker than the usual 4mm stuff, I also bought a sheet of ABS for the trickier areas and for some planned aero stuff for the Prius. I have some aluminum T-bar for creating mounting points and spanning gaps.

I have the use of a new tool that I bought for another job: A pop nut installation tool. Drill a hole, insert a pop nut...POP... instant thread. Actually its more like a rivet. Another brand name is Rivnut. And there is no popping. That should make the installation a bit less difficult. Rivnut Tools from Aircraft Spruce

One of the things I'd like to try is sealing the control arm area of the front wheels. Usually you have to leave that open so the wheel can turn but the MPG competition vehicles use overlapping panels attached to the spindle which rotate with the wheel to seal off the gap. I'll try to find a pic.

The main challenge is finding/creating mounting points. The Previa underside is a lot like a pickup truck with gaping chasms, deep crevasses, vast plains and teetering stalagtites. When I'm under there, deep in the gloom of CV joints, oil and grime, I expect bats to fly, squealing, from the deep caverns of the belly as I prostrate myself for the glory of the aero gods. Great spans of nothing lay before me which will need to be tamed, somehow. I know not what manner of magic will be required for such an epic belly pan installation but it will require much fortitude, strength and vast quantities of beer. I prey you will accompany me on this journey with comradery and song. Together we shall build a belly pan the likes of which mortal man has never seen!!1!

Ahem....

Sorry... Just watched Lord Of The Rings...

On with the panning!

My first accomplishment was the installation of the first mounting bar.



Gaze upon the unending belly of hell and know thy dooooom:



More doom:

[jedi_sol]

For mounting points, are you drilling directly into the frame? or using existing holes?

[orange4boy]

For mounting points, are you drilling directly into the frame? or using existing holes?

If only...I'm drilling into the frame. The nuts I'm using make a good seal with the undercoat and I'll spray it again when I'm done. They are only 1/4 inch holes.

There are some areas near the front that I will be able to screw to the bumper but those are few and far between

[stovie]

sorry going to have to hold off on reading your post laughing to hard!!!!!

[piers.singer]

There's something good in this world, Mr. Marcus...and it's worth fighting for.

By that, I mean good aero.

[Bill in Houston]

Funny stuff. If you scraped off some rust, you could lose a lot of weight, I think. Any progress to report?

[Christ]

Very cool. I wondered when this would come to pass, knowing you couldn't leave well enough alone last year with the kamm, which was also a work of art.

[Christ]

I also submitted this to the wrong part of the library, if a mod would like to fix that... Stupid touch screen.