Here are some pictures of my selfmade ducktail spoiler. Based on the OEM spoiler. I make it with pu foam and shape it to the fundamental form. Then I used fiberglas putty fill all holes and for shaping I use polyster putty. For the stability I used a 120g fiberglas fabric with epoxy resin.

 

....and the finished trunk lid. When I have to much time I will made a mould and make a lightweight carbonfibre trunk lid.

 

Looks great - almost as nice as the views from your garage!

 

Major props for the self made spoiler.. I think it looks great

 

Well done, I dig

 

I like it!

 

Looks good. I'd be worried about the filler holding up in the long (or even near) term. I would think opening and closing the truck would likely start cracks and separation of the foam from the trunk lid.

 

Once the fiberglass cures, the foam isn't doing anything. The glass itself is bonded to the trunk lid. The cured glass supports itself, doesn't need the foam for that.

All the foam does is provide the shape for the glass, and hold it in place while it cures. All it does now is maybe add some sound deadening so trunk sounds more solid when you close it.

 

Yes thats correct. When you like you also can "wash out" the foam with acetone. You don't need it when you have the form. The only problem is the different expansion from the fiberglas and the metal trunk. It's possible to get stress cracks when the sun heat the trunk up. I have make this experience on similar projects. But I very lucky with the trunk until now This is also the reason why I wont to build a mould and make a full composite trunk lid.

 

Very nice