The Golden Egg mod thread. Mostly minivan modding

[orange4boy]

Up late last night working on the coroplast dam.

The frame is mostly aluminium: 1/8" x 2" flat bar and 1/8 x 1/2 x 1/2 angle and tube. The flat bar is nice and easy to bend. I started by bending the bar to the same profile as the bumper. I wanted the slope to match the curve of the Previa as it comes down the windshield.

As you can see from the pictures, there is a huge parachute under the bumper forcing the air under and around the front. Bad pressure, bad. I decided to make the grille block and dam one piece for structural and visual continuity.



There is another strut that goes from the lower attachment, under the van to triangulate the support for the bar.



This is the rough coroplast shape clamped temporarily for marking cut lines.



Here it's just held on with the spring clamps prior to tapping and drilling the #8-32 pan head screws. Will drill pilot holes then use a spiral point tap from Acklands-Grainger in my hand drill which will make the process very fast.



I'm still going to put another aluminium strip on the bottom edge to sandwich the coroplast and another near the top of the bumper where there is an existing detail line. That should break up the vast expanse of Vader helmetness whilst hiding my shameful beer lubricated, dull knife, coroplast calamity cutting. No wait, those are turbulators, yeah, that's it.

I was worried that it would look too huge but I think with the coming trim additions, it should be a pleasing proportion.

Future plans include lexan or plexi headlight covers.

[tasdrouille]

That, my friend, is an airdam. Great job on the van. I'm looking with interest as someday I'll have no choice but to drive one.

[Big Dave]

From one guy with acres of black air dam to another - good looking job.

[orange4boy]

Thanks for all the good words!

I had my first "rolldown your window" hand signal from a ferry worker who was interested in the wheel skirts. (this was before the airdam) He thought they looked like the "spats" on shoes from the Twenties. Wanted to do some custom stuff to his new Honda, liked my spats, so I gave him the Ecomodder address.

Passing on the ecolove...

[orange4boy]

Backing out of our driveway is an ordeal. Short story: Backed over some rocks that stick up (gone now) and popped some screws, bent the aluminium lower bar

Fixed it in 20 ninutes

Picked up aluminium for the top and bottom trim today in the Golden...Rod? I'm getting "the stares" everywhere. I was thinking, why would a big black nothing be so obvious? No grille? It does look a bit nascar, I guess. I will have to order some Ecomodder stickers.

No time to do any testing but it seems to coast forever. The testing will have to wait for my MPGuino which should be coming any day now.

[orange4boy]

This is my quick release vac canister. I have a vac gauge hooked up so I can monitor vac. while braking. I just used standard m-style 1/4" NPT air hose fittings so I can remove the can when I'm working on the car. Sounds cool when you release it. Pshhhhaaaaaa



Update picture of the airdam with the 1+1/2" aluminum trim to match the wheel skirts. Coast down has improved quite a bit although that's a subjective observation.



I would like to add a rubber skirt below the trim to lower the dam but allow things like loading on to the ferry at low tide. anyone know where to get 1/8" x 3" rubber strip?

[bryn]

looks good, looks very good

[PonchoBuick]

I'm glad to see someone going all out on a minivan (of any type!). Gives me hope for my '94 Caravan.

Cheers,
Aaron

[Bullyveldt]

I need to make a dam and rear skirts for my car. I have read all over the site about "coroplast". What is this miracle building material? A heavy type of waterproof cardboard. I'm off to wiki it.....

I think it looks very good I must say.

EDIT....wikied it, and I see a name brand for corugated plastic...hmm now to find some....

[MetroMPG]

Originally Posted by orange4boy

That should break up the vast expanse of Vader helmetness whilst hiding my shameful beer lubricated, dull knife, coroplast calamity cutting. No wait, those are turbulators, yeah, that's it.

From one guy with acres of black air dam to another - good looking job.

This thread is incredibly edutaining. Helmetness.... Right up there with MPaulHolmes' EV conversion!

Remember you don't need a Guino to do coastdown or terminal velocity tests! I'd love to see some stats to prove the Force is ... less.. against you. I think.

Bullyveldt: head to either a sign shop, or else you might luck out at a Home Depot type place. (They carry it at H.D. where I live - $20 per 4x8.) Too bad you didn't know about the stuff when the federal election was on a few weeks back!