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Old 06-02-2012, 02:29 AM   #31 (permalink)
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I went with black for a few reasons--black was readily available, whereas factory matching color would have had to be ordered, and I thought it might look weird with the negative space of the stock grill and foglight hole covers turned red. I wasn't planning on extending the black that far out the sides, but I got carried away sanding. Plus, the black will match my eventual tail.

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Nice job Vman. How do you see out your side mirrors. Seems like there may be some safety issues. When I had an Illinois drivers license I was required to have outside mirrors. It is a fairly common restriction.

Do you have narrow mirrors in your flattish panels?
Nope, just some interior convex mirrors from Autozone. I can see just as well as with the stock mirrors, and Illinois only requires one mirror(!), "so located as to reflect to the driver a view of the highway for a distance of at least 200 feet to the rear of such motor vehicle." So, blocking the rear window would make the interior mirrors no-go, but as it sits it's legal (but not in Washington, where it's registered until the tabs expire later this year).

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Old 06-02-2012, 02:55 AM   #32 (permalink)
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Very nice work! Thank you for sharing
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Old 06-02-2012, 11:00 PM   #33 (permalink)
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Looks good, did you do anything to the bumper to get the glass to adhere better? I almost did this back in 09, but the civic that did the foam/fiberglass bumper back then, he had problems with it cracking off of the bumper. The polyester resin doesnt stick to plastic very well. In the audio world, a lot of times, we'll drill a bunch of small holes through the plastic to get it to adhere better.
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Old 06-06-2012, 02:54 PM   #34 (permalink)
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Looks good, did you do anything to the bumper to get the glass to adhere better? I almost did this back in 09, but the civic that did the foam/fiberglass bumper back then, he had problems with it cracking off of the bumper. The polyester resin doesnt stick to plastic very well. In the audio world, a lot of times, we'll drill a bunch of small holes through the plastic to get it to adhere better.
Actually, I used epoxy resin, which I understand has better adhesion properties than polyester resin to non-porous surfaces like plastics. I haven't had any problems so far (knock on wood).
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Old 06-06-2012, 03:05 PM   #35 (permalink)
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You should be fine then, its rare people at home use epoxy resin. Not only should it adhere better, but its a little more flexible, so it should give a little more before breaking, in case anything hits it.
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Old 07-02-2012, 07:01 PM   #36 (permalink)
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Well, I haven't had time to build my tail, and I'm leaving Wednesday for New Jersey. I did get coroplast full pans on the front and rear of the car (with aluminum under the downpipe and catalytic converter in front after the plastic started melting!) and a couple panels in the middle to cover up the center tunnel. I'm also experimenting with 6 vortex generators on the rear window, after tuft testing without them, with 10, and then removing 4--they're keeping the flow attached now, but if they're having an effect on fuel economy, it's not significant enough to tell. I may try and fab up a temporary coroplast-and-tape box cavity tomorrow if I have time....
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Old 07-02-2012, 09:27 PM   #37 (permalink)
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Looks slick, have a good trip!
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Old 01-03-2013, 08:47 PM   #38 (permalink)
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Well, I haven't had time to build my tail, and I'm leaving Wednesday for New Jersey. I did get coroplast full pans on the front and rear of the car (with aluminum under the downpipe and catalytic converter in front after the plastic started melting!) and a couple panels in the middle to cover up the center tunnel. I'm also experimenting with 6 vortex generators on the rear window, after tuft testing without them, with 10, and then removing 4--they're keeping the flow attached now, but if they're having an effect on fuel economy, it's not significant enough to tell. I may try and fab up a temporary coroplast-and-tape box cavity tomorrow if I have time....
Any pictures of the belly pan?

I'm considering it on my '01 Civic, but not sure if it's worth the hassle.
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Old 01-03-2013, 09:09 PM   #39 (permalink)
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Any pictures of the belly pan?

I'm considering it on my '01 Civic, but not sure if it's worth the hassle.
Once the weather warms up a little I can take some. I'm also planning on re-working the middle of the car with flat bar and more coroplast to make a smoother, full pan.
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Old 01-03-2013, 09:10 PM   #40 (permalink)
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And done! After removing the flashing, I filled the grill and lower fascia opening with expanding foam:





Cut off the excess with a kitchen knife:





Then fiberglassed:



After our hottest weekend of the year last week (97--and it's only in the 50s today), I noticed my temperature creeping up when the AC was running. So I made the radiator inlet slightly larger than what I had in the sheet metal:



Sanding:



Lots of sanding:



Painted:



And on the car!



I adhered to the 10-foot rule; it looks pretty good...from 10 feet away. If I have more time in the future I can go back and clean up some spots, but overall I'm happy with it for how much time I put in. And it looks much less conspicuous than the galvanized steel!
Wow, looks nice, time to photoshop my xA to see how it would look like that

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