Thread: Escort Air Dam
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Old 02-24-2010, 05:27 PM   #14 (permalink)
gascort
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Join Date: Jun 2008
Location: Saint Louis, MO
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Gascort RIP - '93 Ford Escort Wagon
90 day: 43.01 mpg (US)

WifesCruze - '11 Chevrolet Cruze LT
90 day: 31.1 mpg (US)
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Quote:
Originally Posted by theycallmeebryan View Post
gascort, what kind of metal strips did you use for that framing? Is that 1/2" galvanized steel? Where'd you get it?
They're 1/2 inch metal electrical conduit. Available for $2-4 for 10 foot lengths at any hardware store. Totally my best find ever for ecomodding. Materials you need to work with it are simple:
1. Hacksaw (reciprocating saw is nicer/faster if you have one)
2. Hammer (you can bend it into nice, strong, 12" radius bends with a tubing bender) but the hammer works great to bend corners of any radius on the garage floor. It's easy once you do one or two bends.
3. Drill and 1/4" nut driver attachment -
You can buy packs of self-drilling sheet metal screws at the hardware store in lengths from 1/2" to 1.5" in the #8 screw size, and I think you can get longer ones in the #10 size. The screws are really nice - just like mini - drill bits that are one-time use and less than 8 cents apiece if you buy a big package of them. They're sharp since every time you use one, it's new.. and go through the conduit, your bumper, fenders, radiator brackets, ...anything with relative ease.

I have this stuff in use as my homemade armrest support (for the wife), a hanging rack in the basement to help my wife resist temptation to hang clothes on the gas/water pipes, and on my Kammback as well. It's strong enough that you can shake the car by grabbing on the bumper or Kammback, but will easily crumple and absorb crash energy in an accident.
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