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Grinder's 07 STI
Grinder's 07 STI
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Old 08-29-11, 11:53 AM   #31
Grinder34
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Default Re: Grinder's 07 STi. - First Track Day in the STi!

Here's a list that I'll keep updated about projects in-work or to-do for the car:

Updated so higher priority closer to the top!

DIY Intercooler Shroud
DIY Hood Scoop Splitter
DIY Skidplate/Splashguard
DIY Radiator Shroud
DIY Lower Grill Guard
DIY Swaybar dustboots
DIY Swaybar lateral lock

Install Tribeca Horns
Airbox Silencer Delete
Stretch Seat Springs
Red-out Interior Lights
Paint rotor hats black
DIY Brake Ducts

Last edited by Grinder34; 01-23-12 at 06:51 AM.
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Old 09-27-11, 05:26 AM   #32
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Default DIY Undertray

I had this in its own thread in the exterior forum, but I'm copying it over here:

Here's the background. I removed my front subframe and attempted to merely zip-tie the factory splash-guard back into place. The splash guard came off on one side on the freeway (which i managed to fix) and then self-destructed on the track. I decided i needed a piece there, both for engine protection and for aero, but I couldnt find any undertrays that would fit without the front subframe:

Hey guys, so i've been talking with T3h_Clap and I think we're onto something (ok, it was mostly him).

Basically its a skeleton for the diffuser that will bolt to the car. Right now I'm thinking of just four mounting points:
2x front jacking plate
2x front frame (see pic below)



The front would be mounted to the same two holes you see his piece mounted to.

Now, on my car only ONE of those holes is threaded so I've ordered some nutserts to turn it into a threaded hole. If anyone's wondering the existing thread is M8x1.25, so that's what i ordered.

So into those two holes I'd put two long threaded rods, with a nut to keep them in place. The frame would mount flush with the jacking plate, and thread onto the rods. To allow different front clearances (for different lips, etc...) the front of the skeleton would be sandwiched between two other nuts.

I did a 30-second paint illustration:

The black is the front bumper and jacking plate. Blue is frame and bolts. Green are the nuts.

I plan on mocking up a skeleton/frame out of wood in the next week or so, and then seeing if a fab shop can make me something cheaply. Here's an example frame:


From there it would be easy to:
a) weld frame to the skidplate
b) bolt it
c) whatever else.

---------------------------------------------------------------------

It finally stopped raining so i managed to get outside and mock up a preliminary frame out of yardsticks.



In case you're having trouble reading dimensions:

Top: 36"
Middle: 27.5"
Bottom: 4"
Diagonals: 29.5" x 2

For a total of 126.5 inches, or just over 10.5 feet.

Depending on where I find metal (I think i saw in home depot today that they had some 10"x1"x1/8" steel and aluminium), you can definitely shorten bits here and there to end up at 10" exactly.

On the other hand, after assembly of a metal version, i may decide that it's not rigid enough and add more triangulation.

Other important dimensions:
jacking plate bolt separation: roughly 2.75"-3"
Frame bolt separation: roughtly 14.25"
Front-to-back-diagonal: roughly 22"-22.25"


I'll tweak it more and post up some dimensions later, but here are some teaser pics:




The two extra yardsticks are just to help keep the cardboard rigid while i tweak with it off the frame.

---------------------------------------------------------------------

Well home depot has 36"x1"x1/8" aluminum bars for like $6 each or something like that. So i got four, but unfortunately i had to buy a lot of supporting tools too, but I'm sure I'll find good use for them!

Anyways, more details: The hole i was hoping to nutsert isnt big enough for the size thread (m8x1.25) as the threaded hole. My new plan is to spot-weld (maybe glue/epoxy) a nut in place on the underside of the beam over where the hole is. I also need to get a bigger drill bit to make the holes for the bolts in the aluminum. Once those are drilled I can then go about test-fitting and riveting the frame together. Then comes the aluminum flashing.

Hopefully more pics/details/instructions will soon follow!

---------------------------------------------------------------------
I've got v1.0 of the undertray completed.

I've scrapped the original idea of the skeleton with the undertray attached, as my new material is significantly thicker and less "bendy." Its scrap from a friend's splitter project, so I'm not sure the technical name for it, but it consists of thin aluminium sandwiching some PVC. Consequently its very light, but very stiff and easy to work with. Ideally, i'd have the piece be maybe 4" wider than it is, but i got it for free so I can't complain. You can see that the piece isn't symmetrical, as one "wing" is bigger than the other. That's where i'd like the extra 4" on the other side.

Here's a pic of the cutout:


So as I mentioned before, the front frame has two mounting holes, only one of which is threaded:


I attempted to JB weld a nut over the second hole but i dont think i scuffed the surfaces properly and the nut was not very secure. I'm trying the JB weld again tonight. If that fails, I'll get the nut spot-welded in place.

For test-fitting I was unable to get the front passenger side properly secured, due to the lack of the threaded hole, but there *may* be a flutter issue with the wings of the plate. I've identified two holes on each side that i might use (either/both) if this ends up being an issue. If i decide i need to use those holes, it might require cutting a new tray, as the holes are very close to the corner in the big cutout towards the rear of the tray.

Here are the two mounting points to which I'm referring:



The hole closest to the front looks preferable to me, as it is farther towards the edge of the car. The plate is almost exactly 3" below the hole, so if i decide to use that mounting point we'll see if i end up with a spacer or just a sandwiched-nut type thing.
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Old 01-23-12, 06:52 AM   #33
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Default Re: Grinder's 07 STI

It's been a while since my last update.

First, i got an AP for Christmas, so I immediately went stage 1.
Second, i got a GR STI TMIC and put it on.
Third, I got the ThermoTec Turbo Insulating Wrap, awaiting install.
Fourth, I just paypalled someone for a catted downpipe, so lets hope they aren't a scammer!
Fifrth, I removed the Secondary Air Pump from the engine bay.

I think i need to add a few items to my to-do list for the car including fabbing a new splitter to accommodate the larger TMIC.
I may also want to put some sort of screen over the TMIC to help protect it.

Last edited by Grinder34; 01-25-12 at 06:08 AM.
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Old 04-18-13, 09:34 AM   #34
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Default Re: Grinder's 07 STI

Upgrades since my last post. A lot's happened!





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