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Discussion Starter · #1 ·
I have finally completed this project! Terrible weather has delayed my installation but finally we had a day in the 50's with no snow or rain...

I made a pattern and hand formed these from .09 aluminum. I wanted the forward end to flow from the base of the mud flaps, complement the Elise lines, and provide protection from road debris.

I figure I'm all-in for the project at about $150 if you don't count the materials that I experimented with but didn't use. I like the some of the molded CF skirts I see but I'm a cheap bastard and $1200+ just seemed too steep.

Really happy with the results.
 

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Discussion Starter · #2 ·
Here's some pics from the build.

First, I used a piece of paper to transfer the underside contours of the car to a cardboard pattern, then I traced the pattern to the aluminum and cut it out with a saber saw. Then I hand finished the edges with files and sand paper. (This was tedious.) Note also that I changed the final pattern a bit to best match the lines of the car.

I then hand finished and sprayed the skirts with etching primer, painted and clear coated. Next I used my R.O Porter Cable polisher to finish the surface.

I used the pattern to map the drill hole locations, then drilled the skirts and then mocked the skirts on the car to mark the holes with a Sharpie. Next, I drilled the underside with a sharp 1/4" bit and placed the threaded 10-24 fasteners seen here with a tool I rented at my hardware store. (I used a drop of Threadlock on the outside of each fastener to assure a tight fit with the fiberglass underside of the car.

Finally, I used stainless 10-24 screws and fender washers to join the skirts to the inserts.

Bing, bang, boom.
 

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Looks nice...a lot of work for sure eh! Considering where you live I might also add the deer guard to the front of your Lotus! rotfl

Nothing like living in God's Country with 2,000,000 deer! Go Badgers! Mark
 

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Wow, Todd - looks great.

Three things:

- Maybe hit up the edge with some door edge molding to protect them?

- Any pics of the underside to show the attachment?

- Did you make a paper/template (say out of rosin paper)? People are gonna ask for them!

Lastly, return that rivet gun to the store - Frank is probably wondering where it is! :)
 

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Discussion Starter · #8 ·
Hey Jeff,

Yeah, door edge trim is an option. In fact, I bought some but when I saw how nice the finished edge looked I opted not to put it on. I've decided if that edge starts to take dings I'll just "fix" it with trim.

I used an old school technique to transfer the pattern from the car. I took a long sheet of white freezer paper, taped it up to the bottom, and took the broad side of a dark crayon to rub the image on the paper.

If there is demand I'll be happy to make patterns from my pieces. For the more casual DIY person it might be nice if the pattern could be transferred to a CAD file so that a water jet could cut these. That would save a lot of time.

I didn't paint the underside, leaving it bare aluminium, just like the rest of the undertray. We have freezing rain today so I'll have to wait to post pics of the underside mounting.

I like the trim look these skirts provide. It gives the car a slightly wider looking stance without making it look heavy and the lines still flow and compliment the car.

BTW, Frank was happy to get his tool back.
 

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Discussion Starter · #9 ·
Looks nice...a lot of work for sure eh! Considering where you live I might also add the deer guard to the front of your Lotus! rotfl

Nothing like living in God's Country with 2,000,000 deer! Go Badgers! Mark
Got that right! (Actually this shot was taken somewhere near the Autobahn and the car was doing about 100 mph, but deer are like heat seeking missiles here too.)
 

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Wow, I bet that driver was glad the BMW ate the deer and it didn't jump at the last second to windshield height!
 

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That cuz it's in Europe.

A 'Merican deer woulda totaled it and the driver too!!
 

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Discussion Starter · #15 ·
A few people have asked about patterns. I'd be happy to share but it would be really nice if someone could tell me how to possibly transfer the 2-D design to a CAD file, if that then could be reproduced on paper, or better yet, a jet cutter.

Meanwhile, I can simply trace some patterns on to 6 foot pieces of white meat wrapping paper if you want to go old school like I did...

BTW, I honestly thought that mounting would be the most challenging part. With some simple instructions it is really quite easy. It took more time to jack the car onto stands and assemble all the various pieces and tools than it did to drill, set the fasteners, and mount the skirts. The key is to drill the holes in the skirts extra large and then attach with fender washers. This allows for some slight adjustments in fitting if the under-body inserts don't match perfectly to the holes drilled in the skirts.
 

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Discussion Starter · #16 ·
Here's a shot of the installed 10-24 threaded aluminum fasteners. I drilled 1/4" holes, put a drop of blue ThreadLock on the outside of each insert, and installed them with the pictured hand tool. Super easy.




The holes in the skirts were drilled extra large and the stainless screws were inserted through stainless fender washers to allow slight adjustment for fit.
 

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these turned out really good Todd. :up:

$120 for a project that has the look of a mass produced option that would probably sell for over $300 isnt a bad day in the office :coolnana:
 
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