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Old 04-08-2018, 05:27 PM   #1
Hyper
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Member#: 15822
Join Date: Feb 2002
Location: TOPOHTO
Vehicle:
1999 WRB GM6
2.34 LR destroker

Default Need advice on creating a mini brace

I am working on a front undertray to seal air from under the car entering engine bay (so this is NOT a splitter, simply an air diverter)

because I can't get access to alumalite honeycomb panels where I live, I ended up getting composite aluminium (thin layers of alum connected by some industrial adhesive) and the material is soft and bends easily

The tray will look something like that, yellow points are marked to show locations where it will mount to the chassis/subframe/rad support panel





the front of the tray mounts to the rad support panel through squared aluminium profile

what I need to figure out next, is how to reinforce is so that it doesn't flap

I had an idea of using aluminium angle profiles





while this stiffens up things along the tray, the bumper corners is what's left out, and I can't decide how to deal with them

the most simple solution is to lay another alum angle profile perpendicular to the other two, so that it goes from bumper side to bumper side of the tray



this means that I would have to cut the angle side of the bottom profile so that I can lay it flat to the other 2, and I don't like idea a lot because it weakens up the profile, and because they would not lay flat on the tray


alternatively, I can make cuts at the profile base and bend them like this



but this leaves the center section weak

anyway, I am a bit tired and can't thing of a decent solution, so need some input
and no, I can't fab brackets that would go from chassis to the tray bumper sides because there is brake ducting/oil cooler lines in that area
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Old 04-09-2018, 10:07 AM   #2
rtv900
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Member#: 428511
Join Date: Aug 2015
Location: philadelphia
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2016 STI

Default

my first question is:
if you said this material is aluminum layered with adhesive, are you planning on just bolting these brackets to it in many locations?
because you can't weld to that right? if it has adhesive layers?
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Old 04-09-2018, 10:43 AM   #3
Hyper
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Join Date: Feb 2002
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1999 WRB GM6
2.34 LR destroker

Default

correct

the aluminium profile will be rivited to it
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Old 04-09-2018, 12:55 PM   #4
Wayne Suhrbier
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Join Date: Mar 2007
Chapter/Region: South East
Location: Alabama
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2006 STI
OBP

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The bracing on the bottom diagram looks pretty good. If you can weld the cut area on the aluminum it would be good. If not you can cut a piece and lay it on its side inside the bend and rivet it in place
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Old 04-22-2018, 05:53 PM   #5
91 RS RA
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White

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If this material is easy to bend, could you form some stiffening shapes (for lack of a better word) in the material itself? Like a pressed metal panel?
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Old 04-23-2018, 07:57 AM   #6
mcursch88
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Location: CT
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2015 STI
Crystal black silica

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OP, I cannot see your photos. I would like to assist/redesign as I have access to modern press brakes and flat sheet lasers.

as well as SolidWorks 2018
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Old 04-23-2018, 11:40 AM   #7
Hyper
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1999 WRB GM6
2.34 LR destroker

Default

that's odd, they open up from different IPs

appreciate the offer, I am however done with it

ended up making 45* cuts and then welding them, rivets all along



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