Overfender flare creation - LotusTalk - The Lotus Cars Community
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post #1 of 157 (permalink) Old 12-16-2014, 12:06 PM Thread Starter
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Overfender flare creation

So I've got 275s on my SSM car and there are no good looking flares available on the market for our cars. I've never done any composite work before but I'm pretty crafty so I'm going to try to make some flares. The project will consist of forming a die out of foam and body filler, making a mold from the die and then finally, making the actual flares out of fiberglass. Since I'll have the molds, I'd be able to recreate the flares and make them from any composite materials later.

So far, I'm simply shaping the foam. This is the fun part. I'm going to make two different shaped flares (one on the driver side and one on the passenger side) so that I can pick the one I like best and match it on the other side before making the molds.

Here's what the current flares that are made for a Miata look like. I think the rears are ok but the fronts are too small.


I bought some foam sheets from Fiberglast. You can see the Miata flare on the floor next to the sheets.


Next I placed the foam on the tire and started shaving off material from the back of the block so that it would start to go over the body panel. I also laid down a layer of masking tape and a layer of clear packing tape on top of that to protect the body.


Once I felt that the block was carved out enough, I used 3M spray adhesive to hold the block on to the body and I started cutting the foam with a serrated kitchen knife.


More cutting:








It's been a really fun process of subtracting material. I started sanding the 2lb foam with a 60 grit paper on a block and it sands really, really well. I have a feeling these will turn out nice.
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post #2 of 157 (permalink) Old 12-16-2014, 12:17 PM
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Nice work! I love flares, they make everything awesomer.

because racecar
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post #3 of 157 (permalink) Old 12-16-2014, 02:42 PM
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Good job!

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post #4 of 157 (permalink) Old 12-18-2014, 07:38 AM
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Pretty impressive work!

What I want to know is why a guy that can pull this off isn't doing them in carbon fiber?

And while your at it integrate some SP legal canards into them so I can get a set :-)
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post #5 of 157 (permalink) Old 12-18-2014, 07:41 AM
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Awesome

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post #6 of 157 (permalink) Old 12-18-2014, 07:46 AM
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Quote:
Originally Posted by Ryno View Post
Pretty impressive work!

What I want to know is why a guy that can pull this off isn't doing them in carbon fiber?

And while your at it integrate some SP legal canards into them so I can get a set :-)
I'd assume he's going to be doing this in wet fiberglass. Wet carbon fiber offers little to no structural advantage over wet fiberglass because the bulk of the weight is from the resin. Making the fiber component lighter does little to lighten the overall composite. Prepreg autoclaved carbon fiber is a different story.

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My frame, rear subframe, steering rack, A-arms, front crash structure, suspension uprights, and fuel tank are stock.
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post #7 of 157 (permalink) Old 12-18-2014, 07:58 AM
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275 in the front dammmmmn
I run 265 in the rear hahahah

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post #8 of 157 (permalink) Old 12-18-2014, 08:36 AM
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Looks good so far, but will bringing the flare all the way down to the front of clam limit it to Elise fitment only?
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post #9 of 157 (permalink) Old 12-18-2014, 09:14 AM Thread Starter
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Yes, since I'll be laying them wet, I'm just going to use fiberglass. Also, I plan on painting them flat black to match the rest of the add-on parts. No use in CF except it will add expense.... plus, the car needs ballast so this seems like a good place to add it.

Here's the mostly final shape:








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post #10 of 157 (permalink) Old 12-18-2014, 09:28 AM
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Wow the one on the left looks amazing.

Might wanna make that a little extra thick/reinforced near the front though - in case of cone bashing?
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post #11 of 157 (permalink) Old 12-18-2014, 11:05 AM
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Totally my personal opinion, so disregard at will, but I think the bottom looks a bit to "square" and needs a little something.

Aha another thread reminded me of this... the little "kick", aiding with aero.


because racecar
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post #12 of 157 (permalink) Old 12-18-2014, 01:27 PM
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That was my thought too. While they look awesome, I think that bottom corner could be softened. It looks to be about a 3" radius. Make it a 6" radius, and it will hot-er. Nice job!
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post #13 of 157 (permalink) Old 12-18-2014, 02:28 PM Thread Starter
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Thanks for the inputs dudes. I am anticipating how it will combine with the splitter and the more I tuck that edge in, the less the splitter can stick out. It's a balance... but yeah, thanks for the inputs.
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post #14 of 157 (permalink) Old 12-18-2014, 05:31 PM
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Very nice work !

John
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post #15 of 157 (permalink) Old 12-18-2014, 05:34 PM
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You never cease to amaze me.
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post #16 of 157 (permalink) Old 12-18-2014, 10:48 PM
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I love the look and concept of these mate, well done!
My humble suggestion is that the LH version which doesn't close in behind the wheel should be combined with the RH version that comes further toward the splitter.
The body has an issue with expelling air from the wheel well, hence the arch vents behind the front wheels on the Exige to get that air out.

I would suggest you either look to incorporate vents or leave the rear section gapped to aid that effect.
The Lotus Exige GT3 had the idea... (see pics)
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post #17 of 157 (permalink) Old 12-19-2014, 04:46 AM Thread Starter
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Quote:
Originally Posted by KryptonCup View Post
My humble suggestion is that the LH version which doesn't close in behind the wheel should be combined with the RH version that comes further toward the splitter.
Thanks. That's what it's doing. In the first picture it's the same side flare as the 2nd picture. Basically, both flares are shaped the same on the rear end.

I need to do a little more sculpting to the bottom/front of the flare that meets the splitter. It's close but as some have mentioned, it's still a bit awkard. It's good to work to a point and then sit with it a bit so you can see the forest through the trees.
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post #18 of 157 (permalink) Old 12-19-2014, 04:47 AM Thread Starter
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And wow, that car #98 is awesome. If I ever take the body to the next step, I'd like to do something like that.
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post #19 of 157 (permalink) Old 12-19-2014, 04:57 AM
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post #20 of 157 (permalink) Old 12-19-2014, 04:49 PM
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very nice work!!!

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