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Ecky · 03-14-2014, 06:13 PM

Last week, I posted about my accidental boat tail in Success Stories. Shortly after I started on my aeromods, and gave the first of them a few days' testing to make sure they wouldn't catch fire before posting. Although I've had some warping around the exhaust, it doesn't look like it's going to spontaneously combust on me.

Materials:

2x 6'x3' coroplast sheets from Home Depot - $14 each
2 cans flame retardant insulating foam spray - $5 each
7' aluminum "strap", ~$12
2x hose clamps
2 self-tapping screws + washers

In retrospect, I probably should've used exhaust wrap, and might yet if the coroplast deforms too much around it.

Underbody pictures:

Because the previous owner replaced the exhaust with a large diameter straight-pipe, the exhaust hangs a bit lower than the rest of the undercarriage. I had to find some way to allow the coroplast to rest against it without bursting into flames.

I had the idea of using expanding fire-retardant insulating foam spray, and wedged some spacers between the coroplast and the exhaust to hold them apart while it expanded and dried.

Fearing the aluminum strap wouldn't be strong enough to prevent the wind from ripping off my partial-pan, I also filled the gap at the leading edge with foam.

From behind:

7 days, mixed city and highway driving, and so far so good. Tested to hold at up to 100MPH.

The data I collected suggests that my gains are about 6% at 65-70MPH, which is just over a third of the gain I got from my "boat tail", but it's something.

Earlier today I took some of my scraps and made a partial grill block (to be remade more aesthetically later if it works) and covered a small strip in the front under the transmission. At some point I'll probably buy another sheet of 6'3 and just do the entire front, with one cutout to allow for easy oil changes and a second to keep space around the exhaust.

After seeing my finished product, my father scratched his head and asked, "how much longer are you planning on keeping that car? You've already got 220,000 miles on it", to which I replied, "Till it falls apart".

03-14-2014, 06:13 PM	#1 (permalink)
Ecky Master EcoModder Join Date: Dec 2011 Location: New Zealand Posts: 5,077 ND Miata - '15 Mazda MX-5 Special Package 90 day: 39.72 mpg (US) Oxygen Blue - '00 Honda Insight 90 day: 54.69 mpg (US) Thanks: 2,904 Thanked 2,560 Times in 1,586 Posts	Honda Del Sol partial bellypan Last week, I posted about my accidental boat tail in Success Stories. Shortly after I started on my aeromods, and gave the first of them a few days' testing to make sure they wouldn't catch fire before posting. Although I've had some warping around the exhaust, it doesn't look like it's going to spontaneously combust on me. Materials: 2x 6'x3' coroplast sheets from Home Depot - $14 each 2 cans flame retardant insulating foam spray - $5 each 7' aluminum "strap", ~$12 2x hose clamps 2 self-tapping screws + washers In retrospect, I probably should've used exhaust wrap, and might yet if the coroplast deforms too much around it. Underbody pictures: Because the previous owner replaced the exhaust with a large diameter straight-pipe, the exhaust hangs a bit lower than the rest of the undercarriage. I had to find some way to allow the coroplast to rest against it without bursting into flames. I had the idea of using expanding fire-retardant insulating foam spray, and wedged some spacers between the coroplast and the exhaust to hold them apart while it expanded and dried. Fearing the aluminum strap wouldn't be strong enough to prevent the wind from ripping off my partial-pan, I also filled the gap at the leading edge with foam. From behind: 7 days, mixed city and highway driving, and so far so good. Tested to hold at up to 100MPH. The data I collected suggests that my gains are about 6% at 65-70MPH, which is just over a third of the gain I got from my "boat tail", but it's something. Earlier today I took some of my scraps and made a partial grill block (to be remade more aesthetically later if it works) and covered a small strip in the front under the transmission. At some point I'll probably buy another sheet of 6'3 and just do the entire front, with one cutout to allow for easy oil changes and a second to keep space around the exhaust. After seeing my finished product, my father scratched his head and asked, "how much longer are you planning on keeping that car? You've already got 220,000 miles on it", to which I replied, "Till it falls apart". __________________ Ecomodding 2015 MX-5 Miata Honda Insight w/Acura TSX engine 2000 Insight TLC & Build Thread Last edited by Ecky; 03-14-2014 at 06:21 PM..