The alumacore/alumalite is pretty strong. I've ran my for 4 track days ad had a couple off track experiences and it's held up fine. Fairly light for its strength

 

That aluma"lite" is surprisingly heavy (or at least more than i expected). It did feel fairly solid however. I compared it to a similar sign material and it had much less flex to it.

 

ok so does anybody have an opinion on particle board and fiberglass? i looked into it and its a cheap but effective way to do this.
and that cardboard is my template and i do have pre set holes where it will bolt into the bumper.

 

1/8" Aluminum/black powder coated. Cant beat it. Strong, light, easy to work with, resistive to outside elements, reasonably priced, and it looks good. My whole car is outfitted with it, from front/side splitters to rear diffuser. I don’t think there is another material out there that hits all of those points.

 

Would love to see photos of all these parts you mentioned

 

Is there a local place you can source this from? I have seen it places online up to like a 2'x2' but no bigger. Where did you source yours?

 

I am picking up an APR bumper this weekend, and plan to make a splitter in almost exactly the same shape as the OP outlined in cardboard. The material I plan to use is Alumalite. Gavrieli Plastics in North Hollywood (818 982 0000) carries Alumalite in 1/4" thickness, 4x8' panels for $110. I'll post a write-up when I get to work on this project.

My plan:
Posterior attachment: radiator support
Middle attachment: aluminum plates that connect to brackets attached to the bumper beam
Reinforcement: two thin steel plates (1/4"x2") that extend the entire length of the splitter to just short of the front edge (to keep the splitter from flexing at speed)
Anterior support: (only if necessary) support rods that attach the anterior edge of the steel plates to the bumper beam

I also plan to wrap the exposed edge of the splitter in matte vinyl.

 

Ha I would sharpen the edges so that if an animal runs out you will take it out with a clean cut lol no but that's bad

 

alumalite is the preferred method in lieu of carbon, you will see alot of splitters made from it at most scca track days ect. I would also pick up some abs and some high strength 3m adhesive so you can make uprights to duct the radiator as well. Also you can do inverted naca ducts in the sides to mount brake ducts to so your not increasing drag that much by doing it the standard way at the front.

 

I'm learning so much!! Allow me to keep picking at your brains. I really appreciate all the guidance