I have always liked road racing, so one day I got the idea that I would try to make a Touring Car version of the Fast FeLion. The first place I looked to start was a nice big spoiler. This presented a bit of a problem for me, as I haven't tried anything as ambitious as this before. And to tell you the truth I was a bit nervous about ruining my casting. I know they only cost a dollar, but hey, it's my neurosis. Anyway, after a bit of sifting, I felt I had found a donor car with the perfect wing, the Nerve Hammer.
I quickly set about dissecting both cars. After sizing up where I wanted the wing located, I took some masking tape and marked off where the holes for the posts would go. Then came the fun/nerve-racking part. I unboxed my Dremel, loaded up the 191 High Speed Cutter, donned eye and ear protection and set about cutting away material from the inside of the casting. I was careful to stay in the area I had masked off, only taking a small amount of material at a time. It is important to use the top speed on the Dremel to prevent 'zinging' the casting or worse, your hand.
After a few minutes of patient cutting I began to get small convex divots on the outside of the casting. At this point I switched over to my hobby knife to perforate the divots and open up the new holes. After a test fit it was clear that the holes were not quite big enough, which is good because I still needed to square them up. I went manual with a triangle file to finish up the opening, going slowly, and test fitting frequently. Once I was done with the casting I made some modifications to the plastic interior to hold the spoiler posts. I then reassembled the car, added a couple of machine screws and viola!
Phase one is now complete and I could not be more pleased with the result. Next on the order: a nice big air dam.
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