Wow, I need to get into this.. I am just starting to dream of parts I make on my own not just replaces or copies. I am dreading cutting all this foam.

 

I think I will have to do it the old fashioned way for a while before I can afford a laser cutter. and some way to enter in shapes as well. I saw that little arm thing but not sure what it is lol.



If Brute Force Isn''''t working your not using enough...

Profile Template laser cut from acrylic



Modelling foam hotwire cut to template



Testpiece of 3 blocks with surface coat added and sanded, think i'll give this another light coat with a brush then sand smoother before polishing.

i'm using epoxy resin with 20% microballoons and 5% silica

You can always use some Linux alternatives. For example CAELinux, its based on Ubuntu and have full package off CAD, CAM and simulation software(you can simulate how your spoiler will behave in real use, pressures, where is weak points etc). Also its aviable as LiveDVD so you do nbot need to install it to try.

Nice to see things going forward. Keep us posted

 



 


    A $1000 electronic device will always protect a 10 cents fuse

Now I've worked out to use google sketchup, here is the part as I would like it to look.

New Plan!

Cool, i hope we got some pics along the build

 



 


    A $1000 electronic device will always protect a 10 cents fuse

I think i'm going to try a combination of the old and the new techniques, i'll use adobe illustrator to design 2d profiles of the peice, cut these from foam block using a laser cutter i have access to, then stick the blocks together and i'll have something that only needs final shaping, smoothing

cut pieces will look something like this:

Hi,

In my opinion, using computers would be just for rendering an idea.

Unless you can have access to "industrial" technologies like laser/water cutting (for profiles you could fill with foam), or 3d scanner, or cnc routers to build the mold withtout touching anything.

Since you have your final idea well built in your mind, I would go for the 100% scratch built way. Using foam that you shape with sanding paper is a great way to learn a lot during the process, and you still can change anything you want in a design point of view very easily. Any low cost insulation foam will work, and once you're happy you just coat your foam with a layer of 150 g/sqm glass to rigidify it, add bodywork and then allow molding.

Its a long process, but it would cost almost nothing. But hey, thats just my two cents.

Japcarmaniac idea has good side too: a lot less work by starting from an actual volume you dont have to create yourself. But you need to buy one, thats the downside.

 



 


    A $1000 electronic device will always protect a 10 cents fuse

why dont you research all the different spoilers available for the mx5 and find a ducktail type spoiler that you can cut/modify to the one for the mx5. join them up make adjustments with body fillers, smooth it all off and take it from there regarding making composite replicas of it.