DIY wide body / flares, anyone ever tried this?

[charchri4]

Anyone else making their own flares around here?

I'm not a fan of the bolt on flare look and everything that is cool is also stupid expensive. But I figure I can do 100 bucks in 22 gauge, fiberglass and bondo so I'm making my own.
This is my pattern:
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/v7_zpsfe98d050.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/v7_zpsfe98d050.jpg.html)
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/v8_zpsb01bf412.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/v8_zpsb01bf412.jpg.html)

Rather than making a plug and a mold to shape the fiberglass I am making a sheet metal frame to support the shape of the fiberglass and do it in one pass.
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/217201412_zpse51340d8.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/217201412_zpse51340d8.jpg.html)

My plan with the metal strips is to use it as a frame to hold the fiberglass matt in the shape I want it. The holes in them are for bonding. I'll put a layer on both sides of the frame and since fiberglass becomes one with itself when it sets there is no way it will come loose. The strips are welded to the fender and I will also bond it with the fiberglass so it should be a pretty strong structure.

http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/3120141_zps7a0a40ac.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/3120141_zps7a0a40ac.jpg.html)

I know you will ask so I'll just put this in now. The wheels are 17x10 and the tires are 265/40/17s and yes they weigh a ton but I have 450hp and 400 ftlbs of torque to turn them.
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/3120142_zpse7692b13.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/3120142_zpse7692b13.jpg.html)

I know the back needs more girth then this because they have to be bigger than the front even though there is no need for the clearance.
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/rearflare2_zps4222d632.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/rearflare2_zps4222d632.jpg.html)

But I figured I'd press on in the front because if this goes wrong fenders are easy to replace. And there is just so many ways this could go wrong! So I am working the fronts now to get them the right shape and pretty much the same
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/312014_zpsf7b22242.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/312014_zpsf7b22242.jpg.html)

And I have a ways to go!
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/312014c_zpsfba15e6d.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/312014c_zpsfba15e6d.jpg.html)

So besides the obvious construction issues never doing this or even seeing it done this way there is a long list of concerns here. If I go too bold it will look added on, if I go too wimpy the big wheels will look like a monster truck. If the radius at the top of the fender doesn't flow the as the flair or if the wheel arch radus is too different it will look added on. If the front is bigger than that back it will look stupid but I need way more room in the front so how to make the back bigger without it looking empty. And the list goes on...

So I was just wondering if anyone has ever tried something like this and has any tips for me.

BTW the top choice for paint at the moment is blitz black with semi gloss stripes. Like this but not so shiny in the stripes
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/3114_zps8f891c1a.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/3114_zps8f891c1a.jpg.html)
Closer to this contrast
http://i1114.photobucket.com/albums/k534/charchri4/Matte%20Paint/small_zps133c3bd3.jpg (http://s1114.photobucket.com/user/charchri4/media/Matte%20Paint/small_zps133c3bd3.jpg.html)

Yes I know most folks would go black wheels but I really like the 5 spoke nickle wheels. She's way more muscle car than anything else so I think it works.

[Bohman731]

Wow! Props on just tackling this yourself. I am very excited to see the finished product!

[Malibu Q]

I've done similar work on old cars, but built the framework and lip from 1/2" steel electrical conduit. It provides a rigid lip to start from. I just bent it over the tire to get the basic shape.
Looks awesome. Good luck!

Edit: Grind then paint areas to be glassed with 2K epoxy primer for maximum adhesion and no rust problems

[charchri4]

I've done similar work on old cars, but built the framework and lip from 1/2" steel electrical conduit. It provides a rigid lip to start from. I just bent it over the tire to get the basic shape.
Edit: Grind then paint areas to be glassed with 2K epoxy primer for maximum adhesion and no rust problems

Conduit and a pipe bender of course! I should have posted this before I started - what a grand idea! I wonder if a piece of 5/16 or so threaded rod would do the same thing. Give a nice radus right at the edge too. I was planning on just griding the get the right shape of the wheel opening but that is way better. Thanks!

I had not thought about priming any of it before I start glassing so thank you very much. I'm going to have to get off the fence on a color then so I can use the same primer as whatever paint system I go with. Never actually painted a car either so that will be another can of worms!

Thank you!

[Phatmiata]

ugh that cobra is soooo sexy!! :frantic: Excited to see what you come up with, and the final product!!! :popcorn:

[atank]

Good work!!!!!!!!!!

[charchri4]

So the fiberglass on the front ones did not go so well. Not sure why but the first layer down bubbled and pulled away from the frame in several spots leaving rather large bumps to deal with. I was really concerned when I saw this!
http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/2171_zps5f289fa4.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/2171_zps5f289fa4.jpg.html)
I ground the bumps down then patched the holes and built up the areas in between them. The good news is I figured out a way to keep it from lifting like that again and they are starting to take shape and look good now.

In the back I knew I had to start over and be really bold or end up with a monster truck looking Miata. So I took the lessons learned from the front and started with an entirely different approach. I pushed things out as far as I could on the quarter and also went straight up at the top about a 1/2" to give it a muscle car sort of shoulder.
http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/2173_zpsafc4e18e.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/2173_zpsafc4e18e.jpg.html)

I used roughly the same top to bottom curve of the original fender but exaggerated it a lot front to back and came up with this..
http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/32220144_zpsaed3f1bc.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/32220144_zpsaed3f1bc.jpg.html)

http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/32220141_zpsf9418773.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/32220141_zpsf9418773.jpg.html)

The photos don't do it justice they have some pretty sexy curves in them.
http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/2174_zps98062f96.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/2174_zps98062f96.jpg.html)

http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/32220142_zps80f5fff3.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/32220142_zps80f5fff3.jpg.html)

I made each piece for both sides at the same time to keep things identical as possible. I also was very careful to make things smooth so no drill holes this time because that distorted the metal.
http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/2172_zpsddcd2d05.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/2172_zpsddcd2d05.jpg.html)

I'm going to finish shaping and blending the front ones before I glass in back in case I need to change anything and to gain more experience with the fiberglass. It's slow putzy work but so far I have about 35 bucks into it so can't really complain.


PS the current color choice is gloss black with sun burnt copper pearl stripes.
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/copperblackcopy_zpsa6d05c0f.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/copperblackcopy_zpsa6d05c0f.jpg.html)


Something like this but smaller and tad less orange in the stripes.
http://i1114.photobucket.com/albums/k534/charchri4/Stuff%20to%20save%20for%20web/copper_zps0412f967.jpg (http://s1114.photobucket.com/user/charchri4/media/Stuff%20to%20save%20for%20web/copper_zps0412f967.jpg.html)

[charchri4]

A little video update. I hope you can kind of see the body lines here. I just used the pocket point and shoot I keep in the garage but should have used a real camera...


https://www.youtube.com/watch?v=Z5FSa-D4Sxg&feature=youtu.be

[wannafbody]

Impressive work

[HELLIONMX5]

In on this thread. Good luck man. Thats a huge challenge. Looking great so far

[JamieH]

So, this thought is probably a bit late at this stage. But did you use a piece of rolled steel to act as the new fender lip? Very curious to see you get to the primer stage.

[atank]

Looking good "charchri4"..........!!!

[HELLIONMX5]

You want me to drop off my car? How much you charging? Dude i see this already playing out well enough.

[Ihatecars]

Looking damn good.

I'm so excited to see the end results of your hard work.

[charchri4]

So, this thought is probably a bit late at this stage. But did you use a piece of rolled steel to act as the new fender lip? Very curious to see you get to the primer stage.

LOL I wish I knew! I first thought I would just wrap them with light weight fiberglass weave rather than the chopped stuff the rest of the flares are. Then I picked up 20 feet of 1/4" rod to have a nice solid rounded end to the panels. But forming that to the shape of the flares didn't work very well. So I'll probably just wrap them glass for lack of a better solution.

I'm just about ready to shoot the front with a guide coat and I am looking forward to seeing some color on them. I think I'm going to work on the rocker rust this week though. I'm thinking about kicking the back of them out some like the project G stuff.

[charchri4]

Getting closer. Need to do a little work on the wheel arches yet.


http://youtu.be/_HTGtZew0Z0

http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/5220149_zps87612f09.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/5220149_zps87612f09.jpg.html)
http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/5220145_zps928b5927.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/5220145_zps928b5927.jpg.html)
http://i1114.photobucket.com/albums/k534/charchri4/Jenna%20work/5220148_zps64012176.jpg (http://s1114.photobucket.com/user/charchri4/media/Jenna%20work/5220148_zps64012176.jpg.html)

[wannafbody]

Looks good

[HELLIONMX5]

I really really reeeeeealllyy reeeeeealllyy reeeeeealllyy wanted you to rev thst engine. Just once. I love the sound of a v8 with a ridiculous cam.

[charchri4]

Yeah I really love that too! Give this a listen


http://youtu.be/RZGs7C4AorM


https://www.youtube.com/watch?v=88hy73mNQwE&feature=youtu.be

[Cxmoney]

oh hot damn

[HELLIONMX5]

YES!!!!

[atank]

I like!!!!!!!!

[Phatmiata]

the first post had me really scared as to the outcome, looks like frankenstein but wow they look great once all is said and done!! And the best part is it will still look rather factory once painted!!

Nice work for sure!!

[Driftdevil]

Beautiful sounding!

[etikoner]

I just don't quite like how the fender line is flat where it meets the wheel, (to me) it doesn't go so well with the miata bubble shape.

*edit, looks good otherwise.
Kudos on tackling this project yourself.

[charchri4]

I brushed on a guide coat of epoxy primer / sealer yesterday and thought I would post some pix.

http://i62.tinypic.com/2ed31pz.jpg

The front looks good but I'm not a fan of the back. With it all one color the quarters look like a big wart on the car.
http://i62.tinypic.com/zob4vc.jpg

It looks better with the mudd flap on and bumper cover attached but overall I think it's too round and sticks out too far for the shape of the rest of things.

http://i59.tinypic.com/2dons8.jpg
http://i61.tinypic.com/ih6xcl.jpg

It looks really cool in the mirror though...
http://i61.tinypic.com/svosj8.jpg

She’s going to stay in this matte black primer till I am happy with the quarters and I may rework them later in the summer.
http://i59.tinypic.com/1r83kh.jpg

Hopefully the next post in mid June will be all one color and on the road!

[Phatmiata]

what size tire is in the back??

[charchri4]

They are 255/40-17s all around. 275s in the back would help and easily fit but I kind of like to be able to rotate them and can't run the big in the front. Might have to just get over that!

[Hammy]

Really, really like what you are doing here...unique and tasteful and different. Very Good work Sir :)

[wannafbody]

Work the rear flare down to the body crease.

[charchri4]

OK I couldn't stand how ugly it was so another layer of sheet metal and 20 hours of work LOL!
http://i59.tinypic.com/5b42v5.jpg
http://i57.tinypic.com/n5smme.jpg
http://i57.tinypic.com/fdzpmo.jpg
http://i61.tinypic.com/2rg2bl3.jpg
http://i58.tinypic.com/dhfzok.jpg
http://i62.tinypic.com/2hd1xkm.jpg
http://i62.tinypic.com/deqmmd.jpg


http://youtu.be/tcNL7TKlDbk?t=15s

Got rid of the wart look I think but will know for sure with paint. Hope to get it all one color in about a week.

[Benbrg]

This might be my new favorite miata. You should get a smoothie rear finish panel to accentuate the fenders.

[atank]

Oh man that looks great!!!!!!!

[wannafbody]

Good work, much patience have you:)

[WASABI]

Good work, much patience have you:)

http://cdn.geekwire.com/wp-content/uploads/2011/12/yoda-spaceship.jpg

[Sean5294]

The force is indeed strong with this one! I can't wait to see it painted.

[charchri4]

http://i57.tinypic.com/zjf8s4.jpg
http://i59.tinypic.com/fmsb3m.jpg
http://i60.tinypic.com/8w0akw.jpg
http://i57.tinypic.com/10f9rx5.jpg
http://i59.tinypic.com/1zdmcg7.jpg
http://i61.tinypic.com/20ifdrr.jpg

[m00se]

Needs more tire shine ;) i personally think the wheels are to big but i understand why you have them. The flares look great, honestly way better than expected.

[charchri4]

I don't know why but the thing has always looked fugly in photos compared to looking at it in the driveway. It is a satin color that shows a bit more glossy in the photos than it really is too. And yeah it is pretty dirty here being straight out of paint and dusty. Probably give it a bath in about a week.

[tsingson]

Looking good so far. I can't wait to see your cleaned up pics.

[atank]

This turned out very well!!!!!!!!!!!!

[HELLIONMX5]

Looks good

[Malibu Q]

Well done! The flares look good. Is that a rear wing bracket? I'd like to see that fitted. I think a wing would suit your car.

[charchri4]

Yes sir that is a wing bracket! Actually it's a combo wing / luggage rack bracket and one of these days I need to build a wing... :D
http://i57.tinypic.com/25hppcn.jpg

I have a different rack sized to fit my bass drum so I can gig with the car.

[charchri4]

The bad news and the good news. I thought it would be a grand idea to fill the void between the flare and the fender with foam. Till I got it out in the sun and the foam expanded and blew right though the flare!
http://i58.tinypic.com/1zyh28k.jpg

So I spent the next hour creating reliefs for any other uncured foam to escape from. Yeah that whole one step forward 2 back thing... :D

But wait there is great news! SUCCESS! Not one hit on the flares anywhere! I may even drop the car a bit more... :D

https://www.youtube.com/watch?v=WmnmUj0hwCk

Yeah you caught that at the 10 second mark right... LOL!
http://i59.tinypic.com/90ncwj.jpg

[charchri4]

12 months and 10,000 miles after paint and... 2 cracks but both happened in the first 50 miles of driving. No changes after that even with hitting 25 below in a Minnesota winter.
http://i59.tinypic.com/2mmv15.jpg

I don't usually drive it in the winter but did get it out at Christmas for a road trip with my son and we managed to put her in the ditch but no real damage...
http://i61.tinypic.com/6693r7.jpg

I've run a dozen autocrosses and lots of romps well over 100
http://i59.tinypic.com/90ncwj.jpg

And this is a shot taken today with the areo on for a track event.
http://i1114.photobucket.com/albums/k534/charchri4/P1150115c_zpsgieqmddi.jpg (http://s1114.photobucket.com/user/charchri4/media/P1150115c_zpsgieqmddi.jpg.html)
http://i1114.photobucket.com/albums/k534/charchri4/P1150089c_zpsba9yqac1.jpg (http://s1114.photobucket.com/user/charchri4/media/P1150089c_zpsba9yqac1.jpg.html)

I have to say I am as surprised as anyone it has not fallen apart and still sure it will someday but so far I am really happy with it.