Custom Rear Diffuser is in the works!!
 

Hi guys, I'm over here now at LXowners.com to spread some Danko Joy:flowers2: So here is a quick synopsis of the fabrication of our next custom piece to be released, the Danko Rear Diffuser!! :dancingpoop:

Here is what it will look like when It's done:

http://i227.photobucket.com/albums/d.../WithTooth.jpg


First, I decided where it's edges will be (blue line):

http://i227.photobucket.com/albums/d...ffuser0012.jpg

Next, I fiberglassed up the whole area. this will form the rear flange so I can stick it back on with tape later.

http://i227.photobucket.com/albums/d...diffuser10.jpg

Made a box next and poured a bunch of foam into it:

http://i227.photobucket.com/albums/d...fuser_foam.jpg

Next, I sculpted it down more and more, this took a couple of days of serious contemplation and measuring.

http://i227.photobucket.com/albums/d...user_foam1.jpg
http://i227.photobucket.com/albums/d...diffuser_3.jpg
http://i227.photobucket.com/albums/d...r/asdf0012.jpg
http://i227.photobucket.com/albums/d...r/asdf0032.jpg
http://i227.photobucket.com/albums/d.../werew0012.jpg

Next, the idea is to make it the thickness it's supposed to be all over, around 3/8" . I did this by adding several layers of fiberglass and 2 layers of an 1/8" thick core material. It's finally ready to be removed from the car and trimmed down to the edge of the blue line, so more pics are to come!!

http://i227.photobucket.com/albums/d...er/dfg0012.jpg
http://i227.photobucket.com/albums/d...user/df004.jpg

Mo, wow!!!!! that looks like a lot work, that I wouldn't want to do. :). Thanks for sharing the phases that it takes to create a beautiful Danko Product. Eager to see the final result. Btw, I won't ask anymore. Lol!!!

You're welcome, and thanks for the invitation to hang out with ya'll!

thats gonne be sick

Today I got the entire thing grinded to my satisfaction. The next step tomorrow is to start bondoing it up to make it smooth. I will also be extending the lower lip a little further out.

http://i227.photobucket.com/albums/d.../wwwww0042.jpg
http://i227.photobucket.com/albums/d.../wwwww0032.jpg
http://i227.photobucket.com/albums/d.../wwwww0012.jpg

Mo, as usual, looks like a work of art. I see what you mean about extending the lower lip, but you don't think it looks more streamed lined as is? Looks sick! Now will this fit on a 300 or Magnum as well?
Thanks again!

If I want to use honeycomb, it has to be extended like in the original render. The only reason it needs extended is because the lower edge never got the 3/8" worth of thickening material so it is not correct yet, I'll do it with bondo instead.

Extending the bottom edge really did the trick, it is now really looking just like the Rendering I think. I hung the tape in the general area where the bumperettes are gonna be just to try to visualize it. This is really not gonna take that long to finish up, so I think I'll start getting a list of folks who would be interested in getting one for $225. MZGUDZ already has dibs on the first one of course! This is not an official list, just an interest gauge of truly serious parties.

1) MZGUDZ a.k.a. Gudzy
2) ??

http://i227.photobucket.com/albums/d...erdiffuser.jpg
http://i227.photobucket.com/albums/d...rDiffuser1.jpg

looks real good mo. i like it alot.. cant wait to see it all done..