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      06-25-2008, 08:19 PM   #1
Papethova
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Rear Diffuser cutout

This is pretty simple as long as your are comfortable working with tools and cutting up your new diffuser.

To remove the diffuser follow the steps in this thread (http://www.1addicts.com/forums/showt...light=diffuser)

Once you have it removed you need to peel the insert out. I guess you can stick an exacto in the space between it and the diffuser and just cut it out, but to be more precise we decided to remove it before the cut.

From behind carve into the diffuser an 1/8-1/4 of an inch from the edge and cut all around basically in the same shape. The picture shows us cutting a square because at that point we weren't sure how this thing was attached. As it turns out its attached with heavy double sided tape so youll need to cut along the entire length and width of the thing.

After cutting just pop it out. You can separate the piece from the scrap diffuser piece and remove all the sticky tape if you decide to save the insert.

At this point you have options....

1. Sand or file down the diffuser from the back vertically to remove the rough cut. Might be difficult gauging how much to remove and it may not end up straight.

2. Which is what we did, from the front cut horizontally around the opening with an exacto straightening the rough cut you had done from behind.

After completion you should be able to see a strip about 1/8 of an inch thick where the cut was.

Now using a rasp or any grinder carefully grind down the backside vertically until this strip is gone. The strip provides a natural straight line. This plastic is very soft so be careful. You can easily scratch the diffuser and/or remove too much material.

After getting all the excess off youll have a nice smooth straight opening where the insert was.

Take your mesh, place it over the opening on the back of the diffuser, and cut it roughly in the shape of the opening. Leave enough overhang (~1-2 inches) so it almost touches once it bent. Also, youll want to make cuts near the curves so the mesh sits flat with no warping or kinking.

Now bend the mesh so it contours the diffuser. Here we inserted the insert back in to provide support and hold the shape properly.

Apply an adhesive. Im guessing something like liquid nails will work. We had stuff that came with another bumper left over but there was no name on the tube.

Place some coke cans on the mesh and tape it down so it can dry properly.

Leave overnight and reattach the diffuser.

Sorry, I have to attach my pics at the end. I dont know how to get them in between my sentences. I also have to apologize for the poor image quality and lack of detailed pics because I cant stop to take pics while working with dirty hands.
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      06-25-2008, 08:20 PM   #2
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Before and After
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      06-25-2008, 08:22 PM   #3
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Nice work!!
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      06-25-2008, 08:54 PM   #4
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so you drink the coke afterwards?
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      06-26-2008, 03:45 AM   #5
Papethova
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In case anyone is afraid to try it or for whatever reason, I posted in the commercial section

http://www.1addicts.com/forums/showthread.php?t=10622

Also, I can get more of the mesh if you cant find it locally.
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      06-26-2008, 08:41 PM   #6
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Looks good. It might be interesting to see if someone can do the same thing but get the mesh to bulge out in the opening. I have a mental image, but can't think of a good example.
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      06-26-2008, 10:31 PM   #7
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theeere it is. nicely done. ill be doing this for sure, since its basically what i did for the legacy, but on the front
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      06-26-2008, 10:38 PM   #8
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sick! easy diy with a good lookin out come! I did this on the lower bumper of a 850csi and came out awesome.
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      08-15-2008, 03:37 PM   #9
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I don't see the photos
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      01-07-2009, 01:46 PM   #10
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any pics of this on the car? I can't find any
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      01-09-2009, 12:02 AM   #11
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pics on the car, pics dont do it justice. Its subtle in the pics but seems to stand out in person
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      01-09-2009, 12:14 AM   #12
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yea, it still looks really good though, any pics from say 5-10 behind the car? also, you sell the precut insert? Is is all ready to go but for being stuck on?
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      01-09-2009, 06:49 AM   #13
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Nice work!
I like it, look more .:Racing
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      01-09-2009, 01:38 PM   #14
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Quote:
Originally Posted by Add1ct View Post
yea, it still looks really good though, any pics from say 5-10 behind the car? also, you sell the precut insert? Is is all ready to go but for being stuck on?
Pics from 5-10 feet away make it difficult to see the detail. In person its obvious but in pics for some reason the detail is lost.

I can make you one and all you have to do is cut out your plastic one and glue in the mesh per my DIY instructions.

PM me if interested.
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      01-12-2009, 03:28 PM   #15
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Few more pics
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      01-12-2009, 03:54 PM   #16
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so are you selling it painted and shaped with the glue we need, those pics look really good!
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      01-12-2009, 04:05 PM   #17
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I can sell you strips unshaped/unpainted or shaped and painted ready to install. I do not supply the glue.


I had offered to install for some members who were afraid to put a blade to their diffuser. I can still do that but my schedule is tight so it needs to be prearranged.
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      01-14-2009, 06:58 PM   #18
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Anyone who has done this know what the rear diffuser weighs?
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      01-14-2009, 08:02 PM   #19
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that's one hell of an idea. good work!
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      01-14-2009, 09:32 PM   #20
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I’m just curious if this change could affect aero dynamics. Could this change the down force of the rear?
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      01-15-2009, 01:30 AM   #21
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Quote:
Originally Posted by hubs View Post
Anyone who has done this know what the rear diffuser weighs?
The stock piece is super light, a few pounds max (maybe even right around 1). I cant remember exactly, but you can pull it off by removing something like 6 screws and thats it.
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      01-15-2009, 08:56 PM   #22
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Quote:
Originally Posted by bman6074 View Post
I’m just curious if this change could affect aero dynamics. Could this change the down force of the rear?
Any change would be minimal but it SHOULD help, this mod removes part of the rear bumper that acts as an "air-brake" because it catches wind thus slowing you down. The shope of the opening goes raises slightly this would increase downforce.

Unless you are going 200mph and this is was all properly designed expect no effect in the real world.

But it's a cool mod for sure because it saves wieght and helps aerodynamics (very little) but it's also very cheap
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