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Old 11-02-2014, 11:54 AM   #1 (permalink)
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Rolled plastic grill block and air dam



Materials:
I bought http://www.amazon.com/gp/product/B006K8HX56/ref=oh_aui_detailpage_o01_s01?ie=UTF8&psc=1
2x6
1x1
small black self-tapping screws
larger screws
license plate bolts
cordless screwdriver
1/16" drill bit
3/16" drill bit
ruler
2 pool noodles
circular saw
masking tape
square

I boiled the plastic. I decided that I wanted a 13" tall piece of plastic, although I honestly do not know how wide it is. I cut a square edge on the masking tape and put it where I wanted the air dam, from one fender to the other, straight across, with the license plate bolts in the middle of it, and cut another square edge, marking the license plate bolt holes. The distance from the outside of the saw blade to the edge of the [whatever] is 4 1/8", so I screwed the plastic to the 2x6 with the 1x1 on top, so that the 1x1 was 4 1/8" from the edge of the tape. I then cut the plastic to length and screwed it the long ways to the board, with the 1x1 17 1/8" from the edge of the plastic and 4" from the edge of the 2x6. For some reason, I carefully measured the screws, even though it would not make any difference. I cut it again and carefully measured and drilled four 1/16" screw holes 6" apart on each edge and 2 3/16" bolt holes. Finally, I bolted the screws into the license plate holes and put screws through the smaller holes into the bumper. I then shoved a pool noodle between the air dam and the bumper to keep its shape.

I may cut different sized ABS pipes to length and screw them vertically to the air dam.

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Old 11-02-2014, 03:59 PM   #2 (permalink)
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This is a computer simulation of the old air block and grill dam for reference. It looks like I never took a picture of it. The campaign sign was red and white and I eventually painted it black. I bought the materials to put Ecomodder on it, but decided against tarnishing the community's reputation with something that ugly.

I was originally going to post this, stating "Look at this Ecomodder! Just parking wherever he wants!"

I did not realize that I double-parked, I was backing in next to the bluish truck when I did not see the white line. I opened my door and just parked the best that I could.

For some reason, that first spot is extra wide, and the truck parked at the far edge.

So, I went from a red and white coroplast rectangle painted black and melted lawn edging to one piece of ABS plastic. I just need to strengthen the back.
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Old 11-02-2014, 06:40 PM   #3 (permalink)
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I like the first picture better.
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Old 11-02-2014, 06:54 PM   #4 (permalink)
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Quote:
Originally Posted by Cobb View Post
I like the first picture better.
The current one with the one-piece ABS, or the old one with the spray-painted coroplast and melted lawn edging?
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Old 11-05-2014, 12:17 AM   #5 (permalink)
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For rigidity, I suggest

1) screw or tape everything down to make the plastic hold its shape.

2) Line the back side with 2 layers of fiberglass and resin. I that should allow the whole cover to retain its shape and add rigidity.

Since you'll be doing the backside, no need to worry about "finishing" with sanding and bondo.
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Old 11-05-2014, 03:18 PM   #6 (permalink)
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So, I remove the air dam, apply fiberglass and resin, and then reinstall it while it is still drying? Will I have much resin dripping off?

Thank you very much!
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Old 11-05-2014, 05:36 PM   #7 (permalink)
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Quote:
Originally Posted by Xist View Post
So, I remove the air dam, apply fiberglass and resin, and then reinstall it while it is still drying? Will I have much resin dripping off?

Thank you very much!
I was thinking more like

1) remove air dam
2) tape up the bumper
3) remove bumper
4) attach air dam to bumper
5) lie the airdam/bumper face down so that you can work on the backside of the airdam
6) apply 2-3 layers of fiberglass and resin to the backside of the airdam
7) if you get the fiberglass resin from Lowes or home depot, they only take about 20-30 minutes to dry

8) Now you've created a stiff "backing" for the airdam that should contour better with the bumper
9) drill holes and screw the airdam to the fiberglass backing for rigidity

hope this helps
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Old 11-08-2014, 01:06 PM   #8 (permalink)
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For some reason, we have sheets of foam in our shed and I had Gorilla glue, so decided to put them to debatedly good use. I cut one piece of foam to fit the very bottom edge and then another one to fit the bottom grill. That was half an inch too small, so I bought half-inch foam and I was barely able to reattach the ABS using the original holes, although the top edge somehow now fits much closer to the bumper. I tried shrinking it with my heat ray on low yesterday and it did not do any good. I held a 2x4 against it, which prevented it from sagging, but I thought that the only way to make it work was to press a thin strip of metal against it and heat that.

You can see how wide the pieces are and the left edge of the dam was misshapen from lying on the ground. I am going to fit pieces for the edges.

Would resin attach the foam to the plastic well or should I use something else? I could definitely fiberglass the foam, although I would need to sand it down first, and I doubt that would be easy to do evenly.
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Old 11-08-2014, 01:12 PM   #9 (permalink)
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Man, if I still had all of my attachment points for my bumper, I'd have made a new lower engine cover. Maybe an air dam too, but I have just enough scrapeable driveways around here that I'd hesitate.
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Old 11-08-2014, 02:30 PM   #10 (permalink)
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Quote:
Originally Posted by Xist View Post

Would resin attach the foam to the plastic well or should I use something else? I could definitely fiberglass the foam, although I would need to sand it down first, and I doubt that would be easy to do evenly.
yes and no

the resin might detach from the plastic over time since the plastic is smooth, therefore, the resin won't "grip". You can help adhesion by sanding the plastic a bit before applying resin. This should give the resin a little more "grip" to hold onto the plastic. Then to be more secure, screw down the plastic onto the fiberglass/foam

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