Rear Spoiler Progress - Magnum Part II

[Hemissary]

Well, it’s finally done, for Part I go here:

http://www.lxforums.com/board/showth...=1#post1631685

Other projects retained priority (like header install, Aeroforce twin OBDII gauges/Zeitronix wideband combo, etc), so the spoiler was painted as of last evening.

First shots a bit artsie-fartsie, I took it an hour ago:



These shots show the aluminum backbone ready to be permanently adhered to the OEM spoiler using PL Premium urethane adhesive (same stuff used within aerospace sandwich construction). Note the aluminum has been scrubbed thoroughly to remove the oxidation that impedes the bonding process. I can’t stress enough how aluminum prep will prevent long-term delamination/paint separation. It’s critical! In the 2nd shot you can see how I have chamfered the LED holes so more of the LED structure itself protrudes to emit more light:




Here the urethane is filleting along the upper/rear OEM spoiler’s surface. Note also after the adhesive cured I removed the attachment hardware and filled the holes left in the aluminum backplate:



Here I have wired up the nine Luxeon Star LED’s, I chose the Star/C configuration which possess a larger heatsink (aluminum backplate for better heat dissipation). The PN for this application is LXHL-MD1B (44 whopping Lumens each @ 350mA). I had to remove the 0.100” header from the front side before they were useable though (folks may wish to choose the Star-HEX version LXHL-MD1D, still has a (smaller) heatsink with solder pads).



Followed by a continuity test prior to permanent installation:



Given the complexity of painting the aluminum back support “with" the LED’s in place, I elected the lesser of two evils was to first paint the backside semigloss black. This meant having to be very careful during the rest of the assembly process so as not to scratch/mar/paint this final surface:



Here is a quick shot of the LuxDrive 3021-D-I-1000 constant-current buck switching regulator I employed to power the nine LED’s. I adhered it in the old 3rd brakelight opening with the same urethane adhesive. This device puts out clean power in a very reliable and small package (called a puck). Essentially, the 9 LED’s are actually wired as 3 LED’s in series, and 3 circuits in parallel.



Here’s the LED’s permanently installed. I used clear cyanoacrylate adhesive around the base of each LED, then pushed them into the holes I had previously drilled/countersunk into the back support. This positioned and also sealed them and the interior of the spoiler body from moisture. I then used urethane adhesive again splooged around the heatsinks the permanently secure them. Given this LED’s operating temps are
-40C/+85C and average lifespan in excess of 100,000Hrs, I won’t be replacing them in my lifetime:




Finally, the heart of the device, the composite structure I built has been adhered in placed using urethane. I have already removed the masking tape used to position and "squeeze" the laminate to the OEM spoiler/backplate:



Another quick test just to be sure!!



Then it was on to rough-sanding, filling, sanding, primer, sanding, more primer, and finally spot fill. This part of the build sucks IMHO. I’m one of those that can not let even tiny imperfections go – hence a lot of time is required at this stage:



So with PPG Inferno Red (otherwise known as Blaze Red) basecoat, and then some Dupont Chroma-Clear, here is the end result:




Now on to the good stuff:







If I were to guess, it took me a week (say 8-10hrs/day) to actually build this spoiler, it took significantly longer to ascertain what looked right. I still need to color-sand and polish but to needs to cure for a bit. It has some $%^&*@! foreign matter in the clearcoat, I don’t own a downdraft booth

[jules2315]

That is pretty cool that you made that yourself. Must be nice to be that handy...looking very nice when brake lights are on seeing the LED's light up.

You also doing the AMG arent you?

I would like to do that but would need to pay someone to do it for me.

Cheers

[gameover]

Dude that is sweet! Awesome work! Do you plan on making duplicates?

[rwalshphoto]

looks great. I'd buy one

[Shane T.]

Don't like the brake lights but other than that I want one.!!!!
Shane T.

[blackmagnum06]

that looks awesome! great work! are you going to be making these for other members? or is this jsut a one off? not a big fan of the LEDs either, if there was a big strip of the LEDs closer together than that would look cool. but still that spoiler looks awesome great job!

[JonzMgnm]

Nothing is better than an innovative mod, IMHO and this certainly fits the bill! Nice idea and great execution....beans to you, bud!

[mofoninja]

Lookin' Good Hemmisary! The fitment of the spoiler looks perfect!

[Hemissary]

Thanks gentlemen, I'm honored;

The third brake light configuration was the culprit in the delay actually. I was somewhat inspired by the Audi A8's daytime running headlights which utilize a bunch of these LED's along the lower periphery and shine a bright cool white. The spacing is what really caught my eye, a bit tighter than what I did but none-the-less spaced out.
I guess that's it...I was spaced out when I chose this scheme

Then I drove an Aston Martin that had a hi-density row (lots very close together) all along the entire(!) back window...a bit gaudy I thought. Actually...that was the ONLY thing I found gaudy about that piece of art, but after all they are there to enhance safety.

Finally, everyone and their dog has a relatively short length of hi-density row of lights top-center.

I think at night it is going to be a bit disconcerting for folks behind me...especially if they are too close

[Hemissary]

Thanks, years and years of cars and model/fullsize aircraft have contributed to the braintrust so-to-speak...

If by AMG you are refering to the paddle shifters, yes.

	Quote:			Originally Posted by jules2315
	That is pretty cool that you made that yourself. Must be nice to be that handy...looking very nice when brake lights are on seeing the LED's light up. You also doing the AMG arent you? I would like to do that but would need to pay someone to do it for me. Cheers

[Hurst Equipped]

now that is very nice. i love those jet impeller wheels too

[FamilyTruckster]

Nice work man. I wish I could do stuff like that. Now for a pic at night!

[Charg-um@BMC Performance]

A fine job ! Looks great !!

Dang it, I need to kick mine up a notch..

[hell yeah it's a wagon]

Awesome works and looks great!! LOVE those wheels... wow

[AlbertaAMX]

Looks great man, hope I make it to Red Deer Saturday to see this in person.