[CalgaryZL1]

Originally Posted by SOCAL.M6.ZLE

Hey team, just thought id share my progress thus far...
To recap.

Objective.1 - Remove main HX obstruction for cooling and aesthetic improvements.
Objective.2 - Maintain some level of low speed impact protection and front end rigidity.

Photo.1 - Before photo showing the level of obstruction that the crash bar makes...
Photo.2 - With crash bar removed, you can see how much improvement available, but also how much forethought needs to be made for airflow channeling.
Photo.3 - Fascia off, crash bar exposed.
Photo.4 - My solution (first draft)
Photo.5 - My solution (test fit)
Photo.6 - My solution (test fit)
Photo.7 - My solution with bumper on, showing a draft of the custom air diverters...

Logic; although i would have preferred to make this out of aluminum, for lighter weight and easier fabrication, I opted for .125" wall steel tubing. (might consider thinner wall for next version) I used stacked 1x2 to create a bracket from the match plate to cantilever over to the main vertical support (another 1x2) this enables an easy transition from the angled (approx. 10degree) frame receivers. This also provides great front bearing load resistance due to the doubled tub section being welded together, and more linear surface area to weld too, on the vertical support. This also puts the (4) bolts directly in the center of the tube for crush resistance. From there it is some simple geometry to bring an upper and lower support as close to the fascia as possible using 1" square tube (this was a little tricky to test, but luckily the front fascia comes standard with plenty of hand access haha...) (with a future order I might change this to some one piece tubing) I should have the final version of my custom air deflectors done today... and will upload more photos when its all finished. I applied the primer to the frame last night, as well as a few coats of matte black, will finish the tow hook provision this week, confirm final product weight, and she should be ready to rock and roll!

With that said, let me know your thoughts, and if anyone would be interested in me building one for you? If i could get interest in (10)+, I will build a proper jig, and try to streamline the process to make this more cost effective.

My current best guess is... if I could get an order of (10), that I could sell these as options as follows...

BASE: $650 +/- = Frame (no tow hook provision or air deflectors or painting) This would be ready for you to paint or powder coat...
MIDDLE: $1,250 +/- = Frame + Primer + Tow Hook provision + Air Deflectors. All items are primed and ready for you to paint.
DELUXE: $1,450 +/- = Middle option + Painting all pieces matte or satin black (custom colors add $95.

All options would include instructions and all necessary hardware.
Thoughts on the product, design, and price point so far?

Not criticizing just pointers,
I’m a welder fabricator in the concrete and aggregate production industry and do a lot of fabrication and engineering. If you are seriously thinking of doing some production with this awesome design which I think you should, you will have to tweak a few things like add compression sleeves in your section of tubing where it bolts to the car to prevent compression on the tubing allowing to tighten it without any deflection and also allowing you to move to a lighter gauge steel in certain sections for weight loss, large diameter fender washers are not sufficient because they are usually a soft grade 5 washer.
Also boxing in (capping it by welding in a flat bar) any open sections of tubing not allowing water in and strengthening the overall design. We all wash your cars usually with water although some people dry wash but not everyone. And building a fabrication jig to make your life easy for production. I really do love the design, and if you were able to produce them at a reasonable cost with reasonable effort, I think it will be very successful.