Custom Undertrays

[TkrPerformance]

it should not be a problem sense we are just going to make alum ones to replace the oem plactic ones

[123abc]

Originally Posted by TkrPerformance

it should not be a problem sense we are just going to make alum ones to replace the oem plactic ones

My bad, didn't know they came with plastic ones.

[scheides]

Ya these cars come with hood vents, so there's plenty of places for the air to go once it comes through the IC and/or radiator.

[scheides]

Heh I was going to call discount steel for a quote, but guess what, their stuff is available online!

I need advice, they have 5052 aluminum sheet:
http://www.discountsteel.com/index.c.../itemID/83.htm

or 6061 aluminum:
http://www.discountsteel.com/index.c.../itemID/84.htm

I did some measuring:
http://www.scheides.com/gallery/evoundertray

and I figured out that I need about a 63" x 38" sheet.

The above links will give me a price, but the size is listed in .032-.190, is this supposed to be like .032 inches, or is it a gauge or some sort? .125 in the dimensions I want is going to be like $90 for a single sheet of the 5052, doesn't this seem a little expensive? I don't mind spending this much, just want to be sure I'm getting the right thing.

The site says they also offer precision cutting, I might hit them up and see how much that'd be....would be a nice way to reproduce this for other evo owners....

[TkrPerformance]

.032 is 1/32 in
.125 is 1/8 in
.190 is 3/16 in

6061 is aircraft grade alum.
alum is not that cheap to start with. could always go with steel and have them power coated

[Kevin 1G Drummer]

Overheating probably wouldn't be an issue, but it wouldn't be hard to make some louvers in it to pull some heat out the bottom. As far as using some type of plastic goes, I'm not sure if that would be such a good idea. You have to remember that the down pipe would be right next to it, and of the ones that Jet listed there, the highest max temperature rating was only 210*. Also, the one that listed an impact rating was only 1.3 pounds. As far as template material, I would suggest cardboard. I can get pieces more than big enough from my shop from the boxes we get parts in. To me, tag board would be a little too flimsy to work with.

[Shane55113]

We sell those 1/4 turn bolts at my volkswagen dealership (they go in passat bellypans and they dont have the little handles) and we sell those speed nuts too. so i guess if you need a replacement or somthing you know where to get them without waiting.

[JET]

1/8" aluminum is going to be pretty flimsy on a piece that big. I would look at the 3/16". I really love the UHMW, it takes a serious beating. Aluminum will work well too and be slightly lighter, but will dent.

[scheides]

This is really ghey.

To get a sheet of aluminum the size I need, the metal alone is going to cost me $180+ and if I screw it up, too bad (sorta).

To get a thinner sheet of stainless steel (heavier, but stronger), I would go with like a 12ga (1/10") sheet.....~$300

Anyone have any other ideas? Otherwise, if the price is right, Buschur is selling a pre-cut, pre-measured undertray for $175+shipping, no muss no fuss.

[scheides]

Also, looks like I can get regular steel for $70, but doing the math, it's going to weigh 60 pounds! Geebuz....

[FattyBoomBatty]

No ABS plastic sheets? I think Polypropylene would be good, I have some speakers that use that for the cone, it seems to me it would be a great material for an underbelly tray.

The thing is, even if you had a metal tray, if you hit something that is oblong and "tumbling" down the road, depending on its solidity, mass, it would punch a hole right through thin metal. It seems to me that the greater purpose this tray would serve is for aerodynamics, plus shielding from smaller stones and things of that nature, rather than the huge, random piece of flying debris that you hit.

I also want to get one of these, but that plastic or poly sheet from grainger posted above looks perfect for me.

[JET]

ABS won't work at all, it is way too brittle. Polypro is a possibility, but is pretty stiff and brittle also. UHMW is not brittle and takes a lot of abrasion. I am sure Buschur's are plastic and probably pretty brittle in the cold weather (most cheap plastic is), down south you could get away with a lot more.

[Kevin 1G Drummer]

I wouldn't want to use a plastic undertray in any case, considering the close proximity to the down pipe. Unless it was something proven to be resistant to the heat.

[JET]

Just do a little cut away for the DP. Worst case scenario is that it would droop down a bit in that area, but I doubt it. Wrap it and it would definitely be fine.

[scheides]

Ok, I finally FINALLY got this done! I was going to order the buschur undertray at $175, but UPS got sick of shipping them for a 'mere' $75 and upped shipping charges to freaking $200. So, I decided to just get the beatrush undertray and get it done. In the end, I'm SUPER happy with it. MAP got me a killer deal on it, and with some minor modification I got 2 bags of dzus fasteners from kurveygirl.com to fit nicely. These are nice 1/4 turn fasteners used on airplanes, motorcycles, and now evos

Oil change = 4 fasteners
Tow hook = 4 fasteners
Whole tray drop = ~10 fasteners









Drilled out the holes for this panel for the new fasteners:


Aero veins mounted:


Fully installed!


Just in time to use these puppies:


Bring on the snow

[A//// Guy]

That is pretty slick! Nice!

[Kracka]

I'm very impressed with the undertray; definitely a great piece which I'll be getting once my stocker gets all busted up.

[b00stcreep21]

Those looked pretty nice when they came in, glad to see some pics of them on and being put to good use

[SnoEclipse]

Yah, you need to consider heat and airflow as well as water drainage.

[Kracka]

Originally Posted by SnoEclipse

Yah, you need to consider heat and airflow as well as water drainage.

This is why the Beatrush is so far superior to Buschur's in my mind. Buschur's is great for a drag car since its smooth and extends so far rearward, but for a daily-driven street car its lacking in many regards.