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Discussion Starter #1 (Edited)
2nd Update
See the finished design in post #100.



Update
See the re-design in post #85.



Original Post
As seen over here.



is that the OEM modified?
No, this is a completely custom job. While I only worked a few weeks on my rear diffuser, I spent about 8 months working on the lip design and cutting up a lot of bumpers making prototypes. Only in the last two months did I get my final design down, then it was just a matter of getting the right building/bonding/filling materials that can take the inevitable road abuse.

On the OEM lips, the "lip" part starts higher on the sides and slowly fades into the bumper near the center (by the FMIC opening). The idea behind this is to maintain the same clearance as the black plastic piece, which also means the bottom of the lip slopes upwards from back to front.



I wanted something that was level across the bottom, as if it were a continuation of the side skirts.

My inspiration for this came from various members on here, as well as actual products.

Splitters by Individual:



C70 Winglets from Heico:



The slight indentation of the Elevate bumper and the ERST lip:





AJ's C30 lip mod inspired me to make my lip flow smoothly into the bumper. While his design looked really good, other C30 lip mods that I've seen don't seem to fit quite right on our cars. I believe this is because we don't have the continuation onto the fenders.



I love what he did with the facelift on Belle, but I wanted something a little less sharp and less evo-like.



The best examples I based my design off of were the non-existent MS-R lips, the A4, and the scratch guards on Porsches.







The OEM style lips follows the lines of the car well, especially on the sides going towards the wheel wells, so I modeled mine to be similar on the sides. However, you can see that the edge to the lip runs straight around the bumper (no slope) and the bottom of the splitter is level to the ground (it doesn't curve up towards the front).



Sorry for the flashed night shots, it's all I have on me right now and the lip looks a little smudgey from the rain last night. I'll get it cleaned up and post some better pictures soon.





My plan is to fill the gap between the lip and the bumper; one day it'll be painted to match the car.



Multiple times I almost gave up and went the C30 lip mod route, but I'm happy I stuck with my own design. I personally love the way it looks and my opinion matters most on my car. :)
 

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Excellent work man! Fabricating a lip like this is no simple task, it takes a lot of manual labour, testing of prototype donor bumpers and materials to make it work. kudos to you on the results, it looks great and I'm sure the pictures don't do it any justice.
 

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Very nice! What's the method of attaching compared to stock?
 

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Discussion Starter #5
Very nice! What's the method of attaching compared to stock?
Attaching the whole lip? I used the stock lip as the foundation, so it's the exact same. Originally I was just going to make winglets, but then I decided I would make it one whole piece.

If you look in this picture, you can see the level of the stock plastic lip under the FMIC opening.

 

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Oh, so this lip is built "on top of" an OEM? So it's almost sticking off the OEM lip in a sense?
 

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Nice work, glad your enjoying the fruits of ur labor. That's a lot to undertake :thumbup:
 

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Discussion Starter #8
Oh, so this lip is built "on top of" an OEM? So it's almost sticking off the OEM lip in a sense?
Yeah, off the bottom. The top edge is still the original plastic trim.
 

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nice work! I like the subtle OEM+ look :)
 

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Nice one! Ive got a similar project in mind. My girlfriends father has a skoda/SEAT dealership. And he has a wrecked Octavia RS with a splitter at the front. And im getting the front bumper. So i want to make the splitter fit my V50. I hope it works. Nice work with the lip :) What material did you use?
 

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Discussion Starter #12
Over the last year and a half, I've collected many of the bumpers I've seen laying on the side of the road. Having cut something up to match my design, I used heat and hotglue to bend and temporarily hold the lip in place. I then used epoxy to bond he two pieces together and fiberglassed the splitters for added support and to cover the epoxy. Bondo glass on top of the fiberglass to fill in any imperfections, then sanded and painted with truck bed liner.
 

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Over the last year and a half, I've collected many of the bumpers I've seen laying on the side of the road. Having cut something up to match my design, I used heat and hotglue to bend and temporarily hold the lip in place. I then used epoxy to bond he two pieces together and fiberglassed the splitters for added support and to cover the epoxy. Bondo glass on top of the fiberglass to fill in any imperfections, then sanded and painted with truck bed liner.
:thumbup::thumbup: That's hours, hours and more hours, so much that you've lost count. Again great work, nothing is more satisfying right now to see your product completed. Ask me how I know ;)
 

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Good job on the custom work! ...looking forward to the finished product.

I've had quite a number of custom ideas, some turned out good. Some, after all the time taking things apart, I realized it just wouldn't work. Lol. Glad your custom lip worked out for ya. Cheers!
 

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i just saw this after some time away. NICE JOB MNIWT!!!!
 

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Discussion Starter #17
Alright, I'm bumping this thread back up because I've hit a stumbling block with the re-design. I'm not ready to reveal the new design just yet, but it is a three part lip that is going along the lines of this...



Because it's hard to visualize on an S40, here is my question to all of you:

Should the middle remain open like the picture above?
Should there be a splitter plate in the middle?



Or even something like this?

 

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definitely like the look of a middle splitter
 

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Discussion Starter #20
Two weeks later and I give up. There's no way to get this middle splitter design to look right on the pre-face lift without it starting to get costly.

Time for the back up plan! :D
 
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