New front 930S spoiler and new front mount oil cooler... questions?

[x98boardwell]

Here is the link to the turbo forum. Any help is appreciated.

New front 930S spoiler and new front mount oil cooler... questions?

Thanks,
Bryan

[Buckterrier]

I can help with the body questions. I made brackets from stock bought at Ace hardware. As for the bellows you need to drill holes in the valence. I think I used 5mm bolts, two per side. I didn't have to remove anything from mine, (GT Racing), but did add material to fill the area under the bellow.
Sometimes the things just don't fit very well. If I can be of more help sent a PM with a phone number and we can discuss .

[x98boardwell]

Mark,

Thank you very much. Your spoiler also sticks out slightly past the bumper like mine. I thought I was alone on this one.

The material that I need to remove is very minor and I do see where I could add some below the bellows as you mentioned. Do you happen to have any pictures of that process? Where did you mount to the bumper (not the wheel arch)? It seems because it sticks out so far that there is little material to grab onto. Pictures of this?

Lastly, did you add an oil cooler up front? If so, how did you route the lines to the other cooler?

I may PM you if i have any more questions.

Bryan

[Buckterrier]

Bryan,
The gray area on the unpainted valence pic is where I added epoxy. Purchased two of those epoxy sticks at Ace. You can pretty much mold to shape then file and sand to final shape.
As far as attaching to the bumper, I clamped the valence to the bumper as you have then drilled holes in each 'corner'. I think I used 8mm bolts, washers, lock washers, and nut. I may be able to take a pic of that tomorrow. I drilled two on each side. I couldn't get a good angle in the front but it doesn't need fastened there anyway. It's a nice tight fit. And yes they all stick out a bit.
I left the oil cooler in the stock postion in the right wheel well. Certainly we can talk if you'd like. Good luck.

[Buckterrier]

I found a couple pics showing the bolts holding the valence to the bumper. Hope this helps.

[x98boardwell]

Yep, that is where i drilled my holes as well. I will have some more pics tomorrow. I bought rubber washers as well to help so it wouldn't vibrate against my bumper.

I will get the filler tomorrow. Thanks for the heads up on that. It should be easy.

I like the fog light idea. I think I will do that unless I figure out a way to mount to the bumper so the spoiler doesn't have to deal with the weight.

Bryan

[Buckterrier]

Originally Posted by x98boardwell

I like the fog light idea. I think I will do that unless I figure out a way to mount to the bumper so the spoiler doesn't have to deal with the weight.

Bryan

The top of the foglight bracket is attached to the bumper also, thru the valence, and bolted like the attaching bolts so the stress isn't on the valence. Would be great to see some pics. Like the idea of rubber washers. So far so good with mine.

[x98boardwell]

Thanks for all the pointers. I will be adding a aluminum cutter/splitter to the bottom of the spoiler so that will offer the rigidity that I am after and allow me to attach some support brackets to it.

The oil cooler should be here tomorrow so I can mock it up before I send the spoiler to the body shop for prep and paint.

Here are some pics so far. I have an issue with the fog lights. One side seems to fit in well and the other looks like crap. I may have to take away some material here to get it looking good. Anyone have this same issue?

I also will be trimming the rubber washers that you can see just above the fog lights where it meets my bumper. This is just a mock up so I wasn't worried about them now. Lastly, in the first photo I was able to use the bracket from the original spoiler were it meets the fender. I just flattened the edges and trimmed it up a bit and now I have studs that I can use and it worked well.

Bryan

[don911]

You can also move your bumper forward a bit. I did one of these a couple weeks ago. I replaced my bumper shock with euro crush tubes at the same time. For some reason, the bumper moved forward a little with the crush tubes so the valance sits closer to flush. Mine was about 1/4 inch out before.

[Buckterrier]

Bryan,
I also had to remove material in the foglight opening. Used a rasp then a file etc. Looks like you could take a bit away from the right side also so it's looking straight ahead. Also, (I learned the hard way), when you make the foglight brackets think about making slots instead of just drilling holes. It will save a lot of frustration!
They aren't perfect by any stretch but they work and are sturdy. I only have hand tools so not to bad. The notch is because I didn't think about the brackets when I drilled the valence mounting holes. Had to notch them to clear bolts. An engineer I'm not!!



Don, that fits really nice, what kind is it?

[don911]

Don, that fits really nice, what kind is it?

It's the 930S same as your except from Rennspeed. The fog light holes were fiberglassed over and the oil cooler opening hasn't been cut out. I also had cut the area behind the bellows and use the factory piece. Was the only way to get it to fit without more fiberglass work.

[x98boardwell]

I added pics below with the fog lights (resting there... not mounted yet) and the oil cooler.

In addition to the oil cooler I have also added pic's of my 3/16 thick sheet of aluminum. It is 22 x 60 inches and I will lay the spoiler on this to draw out my splitter. I called a few metal shops locally and then finally found one that I liked and they ended up selling me this piece for $50 cash. A few other places wanted $250... quite the variation so be careful when calling around.

I will mount the cooler tonight... hopefully and then can figure out the routing of the lines. Any ideas on how to route the lines from the new front cooler around or on the side of the fender cooler? It does not look like there is much room behind the headlight buckets. Any pic's would be great.

Thanks,

[Chakka71]

Don911
What bumper is that? Where did you get it? I like the idea of eliminating the fog lights alltogether. I'm looking at doing the same idea as you guys are discussing. Looking at GT Racing, but open to some other companies. Just trying to keep the dollar and cents in check.

[don911]

Originally Posted by Chakka71

Don911
What bumper is that? Where did you get it? I like the idea of eliminating the fog lights alltogether. I'm looking at doing the same idea as you guys are discussing. Looking at GT Racing, but open to some other companies. Just trying to keep the dollar and cents in check.

Mine is a 930S valance from Rennspeed. The fog light holes have been fiberglassed over and oil cooler opening was left uncut. Also, the area behind the bellows didn't fit so instead of doing a lot of fiberglass I cut it to fit with the factory metal piece.

This is the one I bought. Don't know if makes any sense dollar wise. Shipping was $125. Factor in the cost of fiberglass and paint and it was quite a bit more expensive than I'd planned.

http://www.rennspd.com/P_Detail.asp?PID=573&Task=STD

[x98boardwell]

Mounted the cooler top to the bumper. The bottom is mounted to the center bolt that holds on the protection bar for the A/C condensor. They will all have rubber washers when mounted for good.

Enjoy,

[Buckterrier]

Looks awesome bryan. What are you going to use for a grill? I have a sheet of the same mesh I made mine from only it's SS.

[x98boardwell]

My spoiler came with a mesh grill. You can see it a little in the first couple posts on the thread. I think it should be fine and basically shade the cooler so you will not be staring at the cooler by itself.

I will keep you posted on the progress this weekend.

Bryan

[x98boardwell]

Oil cooler is installed and she will be started after the holiday weekend. All lines are AN-16.

I used a 150 degree fitting for the line off the fender cooler (the 120 and 180 degree will not work). It really helped face the line where I wanted it to go. Also, put in a new seal and rubber hose where I cut the tin to ensure the lines will not slowly be cut over time.

Enjoy,
Bryan

[x98boardwell]

Here are some pics of what has been done. All ready to go on the car.

1) Used foam between the seams to help support load and resist vibration
2) Included pics of how I mounted the fog lights. I am sure there are better ways but this is solid and I wanted to mount directly to spoiler
3) Had to adjust oil lines to accommodate for fog-lights on passenger side. I used 45 degree A/N fittings which helped to direct the lines up, down or back away from the fog lights.
4) The spoiler turned out great from my body guy. Not bad for $100. He works at a dealer and it would have cost $350 if I took it to them first... I'm happy.

Enjoy!!

[x98boardwell]

I thought I would post the finished product. Thanks to all of you who helped.

Enjoy!

Bryan