Ok, so Kanchi did a pretty good job on the thread with showing how to make it, but here's a step by step on how i did it for all those that were asking for it. I'll be honest, it's a lot easier than i thought it was going to be even though Kanchi kept telling me it is super easy.

this is the parts list that i stole from kanchi. My parts list is a little different because i bought extra because i'm making two. i'll put what i bought next to it. minus the prices because i don't remember. i just know that for all the parts for 2 of these it was around 150.

Parts list:

4'x4' sheet of abs ~ $40 8'x8' sheet of abs 1/8" thick

2x 6' piece of aluminum angle "iron" ~ $6ea 2x 8' piece of aluminum angle iron

3/16" pop rivets, lots and lots ~ $3 i bought two 50 packs

6' piece of 5/16" "all thread" ~ $8 2x 6' 5/16" all thread

16 x 5/16" nuts ~ $2 50x5/16" nuts

16x 5/16" fender washers ~ $2 50x5/16" washers

also one thign that wasn't listed is 6 ft of angle iron that has holes in it.


1x tube of sealant (for the holes to be drilled in the bottom of the trunk) ~ $3

So total cost of materials is around $70


Tools needed:
some of these tools i used, some of them i didn't.

Jig saw with high speed blade - i used a saber saw instead

Coarse & medium files - i used a dremel for moar powaaa

Drill with 3/16" & 5/16" bits

1/2" wrench - i have a wrench set, i'd imagine i'll need a 5/16" for the nuts on the all thread

Pop rivet gun (that accepts 3/16" rivets)

4' straight edge

Wood-working square

..I think thats all

now, before i start, i just want to let everyone know, i was just kinda winging it and doing it as i go. so do this at your own risk. the cool thing about abs is if you didn't cut enough it's easy just shave off some.

also, another thing, is i forgot to take some pictures before i went on to the next step. so, sorry

first thing i did was go and find some huge boxes of cardboard in the trash that people were throwing out so i could make a template. i took the cardboard and then held it up to my bumper and then just started cutting until it looked like it would fit and then i take off as needed. the fins i kinda just made them. didn't really measure or anything. for the exhaust, it was easy because i only had to worry about it on the angle, no where else, so you just have to make the template go up to a couple inches away and follow it.

and thats what my cardboard templates look like.

next, you have to take your cardboard template and trace it onto your sheet of abs, and then cut it out. I'll give you this tip. cutting abs sucks. after you cut it, the plastic melts back together. i tried to use a pnuematic cutter wheel, and then the saber saw. both just melted back together. so i would cut once, then cut again to actually get it to separate. after that i set up a sander, forgot the name of it though. and then used that to smooth out the edges and make the formation perfect.

thats the fins and the small part of the underside because i already had the big part with the aluminum on it. if it goes right it should look like that.

then you have to cut your angle aluminum for the straight edges of the plastic. i used a dremel with a cutter wheel because my pnuematic one broke

for the parts that meet at the corners, you'll see in the next pic, you need to cut the angle aluminum at an angle so that it doesn't go over.

then after all that is cut and measure perfectly, you have to mount it to the plastic with a bunch of rivets. and take your time on th
is part because if you try to take a shortcut like i did, it's not going to go well. just drill one hole, pop a rivet, drill another hole, pop a rivet and so on. and use clamps. they're a life saver. because i did this by myself, if i didn't have clamps i would have cryed probably (not really. it wouldn't have been that bad)

as you can see i have extra holes because i tried to drill all the holes at once, without a clamp holding it in place on both ends. needless to say. none of them lined up lol

after you get it all riveted up (i put rivets about 3 inches away from the last one) it will look something like this!

the fins are on the wrong side, i just taped them up so i could see what it would look like.

theres another angle of the finished product.

one thing you want to make sure of if you're going to be having the fins on it, is to make sure that they won't be invasive of the little things that stick up off your rear bumper. i don't have a picture of them, but once you look at it, you'll see what i'm talking about. I mounted my fins in a bad spot and ended up having to cut mine off. not a big deal i guess because my front ones broke off on their own.

INSTALLATION!
first, take off the rear bumper. it's fairly easy. 4 clip thingy's 2 bolts and 2 screws then just pull it off. theres tabs that hold it on, but with a little bit of pulling and not being scared you're going to break your bumper, it'll come off.


after your bumper is off you'll have to look and see how you want to bolt the diffuser up. I used the mounting location of the tabs that come off the bumper, and some brackets that i made.

so the first thing you have to do is measure the distance for the brackets and then using the angle iron with holes, make your bracket. I measured from the thin piece of metal to a frame member thing. It's right where the heat shield for the stock exhaust goes. you'll see what i'm talking about.


after they're cut and measured and set up you need to mount them. in order to do this, you have to drill all your own holes. the frame spot isn't as bad as it sounds. it's not too thick and i just hammered the heat shield out of the way in stead of taking it off because it was more fun whacking it with a hammer.

and yes, for this part you need to have a friend goofing off in the background. otherwise it just doesn't have the same effect.

next you need to cut the all thread to mount the brackets (or you can use bolts) and then also to go down into the diffuser to hold it up. One thing i forgot to mention is that you'll need to drill holes in the diffuser once you line up where it's going to go.

i cut these to 11 inches. Which is wayyyyyyyy longer than what i needed, but i figure with excess, i won't have to remake anything. and it was actually pretty easy to mount it and get aligned right having them hang down so far.

then you need to take those long pieces of all thread and then bolt them up to your mounting points.

it looks really funny at this point.

before putting the diffuse on, you need to take nuts and thread them up decently high on the all thread as on every point you'll have a nut and washer on the top and bottom.
and then once you're done with that you can put the diffuser on followed by a nut and a washer so it doesn't fall. and then start threading up to go where you want it to go.


then, after that you just have to thread the bolts up and down and whatever to get it to go where you want it to go. i actually probably only needed about 5 inchese of the all thread but it was wayyyy easier this way. after i had it on where i wanted it and the bumper on perfectly i cut the all thead to be short. after that, i drilled a hole in the diffuser where the pull out tab thingy on your bumper and splash gaurd in your wheel well goes and then used some all thread to make my own bolt to support that.

I had to cut out a little bit of the splash gaurd in order to fit the diffuser, but it's not seen anyway so you wouldn't notice it no matter what.




and theres the finished pics that i just took.

then after this, hopefully you get to enjoy it like i did, and go out and race it that night

 

just wanted to let everyone know, that it's completely installed and looks amazing.

The feel of the car when going down the freeway is a lot smoother too. My steering wheel used to shake because i have my tire pressure a little low for racing, but it wasn't shaking almost at all last night. basically immediately after installing it i was doing 100, and it held up great. even with it only being an inch away from my exhaust it doesn't melt or anything. the aluminum when i touched wasn't even hot.

when i make the second one there are going to be some things that i would do differently for sure because i had to cut out a few things on the oem stuff, but nothing too major.

all in all though, i'm very happy with the finished product, and can't wait to put my front splitter on so i can have a an aero car! haha

 

Looking good so far! Personally I wouldve made the fins a little shorter, but cant really judge it till its on the car. I wonder how hard it wold be to make one for my 5A rear lip and have it extend all the way to back somewhat.

Pics are showing up for me

 

pic installed on the car?

 

Watching for installation

 

installation will be starting in the next few minutes. so in a couple hours (hopefully) pics will be up!

 

watching

 

watching.

 

Nice fins

 

more pics with bumper on and car on the ground?

 

X2 on pics!!

 

it's going to happen. i'll take some today when i get home!

 

pics uploaded

 

What was the time frame on that?

 

I could have done it in a full Saturday. But I did all the cutting and shaping of the plastic one day after work. Then I did the rest in about 6 hours. But it wasn't straight. My and my friend goofed off a little bit

 

very original, i think could look a lot better with some more added to it. i like it though, no one makes a splitter for the tc!

 

Kool... I'm going to try to make one now.

 

i'm thinking about adding more. and i have to make another one for a friend. so i might be able to refine the production process a little bit.

i was thinking of adding more full length fins in between the 3 that i have now, but not so big. just to add a little bit more to it.

 

if you're putting the fins on it, i would recommend waiting to do that until it's fully on the car. my diffuser isn't 100% straight so the fins are a little crooked because of it.

 

Good write up!