How to Make a Simple Fibreglass Car Wing/Spoiler

Summary

In this video, the process of creating a custom automotive wing is detailed, starting with the materials needed, including foam core, aluminum brackets, fiberglass matting, and resin. The construction involves cutting, shaping, and assembling various components, such as the support brackets and fiberglass layers. The wing is designed for a car, featuring adjustable angles like an F1 car, and includes custom end plates for added downforce. The final steps include attaching the wing to the car and testing it, with a lighthearted reflection on the wing's large, dramatic appearance.

Takeaways

• 😀 Start by selecting a foam core for your custom automotive wing, which can be cut to the desired shape by a foam supplier.
• 😀 Use aluminium L-section to create mounting brackets for the wing, ensuring a secure fit to the foam core.
• 😀 Practice using a blowtorch to sink metal brackets into the foam core, using freezer spray to control the sinking rate and avoid mistakes.
• 😀 After cutting the foam core, use one half as a jig to mount the wing during construction, ensuring correct bracket placement.
• 😀 For an experimental wing, install pressure tappings in grooves, routing and fiberglassing them with PVC pipes for added functionality.
• 😀 Wear gloves when handling fiberglass to prevent irritation on the skin while working on the wing's structure.
• 😀 Lay down a resin layer on the foam core, then place fiberglass matting over it, ensuring proper coverage and resin saturation before flipping and repeating on the other side.
• 😀 After fiberglassing, trim the sharp trailing edges of the wing with a hack saw to smooth them out for a cleaner finish.
• 😀 Build a steel frame to mount the wing securely on your vehicle, considering an adjustable angle of attack similar to an F1 car's wing.
• 😀 Laser-cut end plates are essential for providing additional downforce, and should be mounted with small supporting brackets for stability.
• 😀 Use epoxy adhesive to attach the brackets and ensure that they are securely bonded before clamping and allowing them to set overnight.

Q & A

What is the first step in making an automotive wing?

The first step is to obtain a foam core, which can be cut by a foam supplier to the required shape. This foam will form the base of the wing.

Why is it important to use aluminum L section for brackets?

Aluminum L section is used to create the mounting brackets for the wing, as it provides the necessary strength and stability for securing the wing to the car.

How do you attach metal brackets to the foam core?

You can use a blow torch to carefully heat the area where the metal brackets will sink into the foam core. Freezer spray can be used to slow the process if necessary.

What is the purpose of cutting grooves into the foam for pressure tappings?

The grooves are meant for fitting pressure tappings, which are useful for testing the aerodynamic properties of the wing, such as airflow and pressure distribution.

Why is it important to cut the fiberglass matting before laying it on the wing?

Cutting the fiberglass matting beforehand helps save time and effort during the application process and ensures a more accurate fit on the wing.

How do you apply fiberglass to the wing core?

Start by applying a layer of resin to the wing core, then lay the fiberglass matting over it. After placing the fiberglass, coat it with another layer of resin to secure it in place.

What is the purpose of the steel frame that is welded for the wing?

The steel frame is built to securely hold the wing onto the vehicle and allow for adjustments such as variable angles of attack, similar to an F1 car's adjustable wing.

What are the end plates for the wing, and how are they made?

End plates are essential for improving the aerodynamic efficiency of the wing by increasing downforce. They are made by laser cutting metal plates, which are then mounted to the wing.

Why is it necessary to use epoxy adhesive to attach the brackets to the wing?

Epoxy adhesive, like Araldite, is used to securely bond the brackets to the wing, ensuring a strong connection that can withstand the stresses of driving.

What is the role of the trace wire between the end plates?

The trace wire links the end plates to each other, reinforcing their structural integrity and preventing them from moving or detaching under force.