BUILD THREAD A Teenager and His Malibu Wagon.

Longroof79

Rocket Powered Basset Hound
Oct 14, 2008
11,667
113
Gainesville, Fl
I did a small photoshop a little bit ago for what I would like to do for my front air dam. View attachment 201402
The cut out area I have will be a bit smaller but the idea Is that I can have a bottom feed radiator while at the same time reducing drag on the under body. I've looked into making a body pan for some more efficient drag reduction and more down force but it doesn't seem like an easy task with these cars. Mostly because things just sit to low to make an under body pan not drag everywhere since this is a daily driver. So for now ill be making a front air dam with something that can bend if I scrape on something. (Maybe garden edging)
I'm doing all this instead of buying a fiberglass bumper/air dam combo because money of course and i would be afraid of cracking a fiberglass air dam after I do a paint job on the car. Also because I'm not the biggest fan of the one piece look.

As you guys were asking. Yes, I will be doing the rear bumper too because also not a fan of the one piece look of a roll pan. Ill probably be bugging LongRoof79 about how he did his because his rear bumper looks freaking awesome!
Also ordered some new LED headlights last night. The current ones have water in them and just aren't bright enough to be considered safe to me.
Nice design on the airdam. A tip for you, you can take it or leave it. Another option would be to use the rear window air deflector up front under the bumper using a few brackets. It doesn't look bad either. In fact I had it on my car at one point and then went back to the original air deflector and then back to the SS airdam. Btw, you're welcome to bug me all you want.
Here's my build thread. https://gbodyforum.com/threads/working-on-the-wagon.33260/
 
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oldsmobile joe

Royal Smart Person
Nov 12, 2015
2,028
113
mpls
Nice design on the airdam. A tip for you, you can take it or leave it. Another option would be to use the rear window air deflector up front under the bumper using a few brackets. It doesn't look bad either. In fact I had it on my car at one point and then went back to the original air deflector and then back to the SS airdam. Btw, you're welcome to bug me all you want.
Here's my build thread. https://gbodyforum.com/threads/working-on-the-wagon.33260/
Any pics?
 
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78Delta88

Master Mechanic
May 23, 2022
300
43
SW Arizona
I'm wondering if the fillers can be made on a 3D printer. Never heard of it being done before, but doesn't mean hasn't happened or tried. On the bumper shocks, I would suggest 3/8 or larger bolt all the way through. Even small bump will be enough to dislodge a threaded set screw. A large hit ... It won't matter.

Air dam mock up or keep as final you can always just use polyethylene sheet. Think Grainger or McMaster Carr. Maybe mock up with strips of corrugated box for template. Transfer template to large flat lid of Rubbermaid Container. Easy to cut with knife, paint with plastic dip and drive around for a while. After a few weeks will give you idea of how bad it gets dinged up as daily driver and you wouldn't have much $$ tied into it. Heat gun will soften enough to bend and when cool will keep shape.

I'm just digging on the wood jack stands. I think could be the next Harbor Freight kit for the DIYer.
 
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blairc_789

Apprentice
Thread starter
Jun 18, 2021
50
33
North Carolina
I'm wondering if the fillers can be made on a 3D printer. Never heard of it being done before, but doesn't mean hasn't happened or tried. On the bumper shocks, I would suggest 3/8 or larger bolt all the way through. Even small bump will be enough to dislodge a threaded set screw. A large hit ... It won't matter.

Air dam mock up or keep as final you can always just use polyethylene sheet. Think Grainger or McMaster Carr. Maybe mock up with strips of corrugated box for template. Transfer template to large flat lid of Rubbermaid Container. Easy to cut with knife, paint with plastic dip and drive around for a while. After a few weeks will give you idea of how bad it gets dinged up as daily driver and you wouldn't have much $$ tied into it. Heat gun will soften enough to bend and when cool will keep shape.

I'm just digging on the wood jack stands. I think could be the next Harbor Freight kit for the DIYer.
I have a 3D printer and I've done a couple prints here and there, but I think bumper fillers would be out of my skill level for now. Although they are reproduced with an ABS plastic. But with 3D printing I also may look into attempting to 3D print the little plastic bolt caps that go on the wings for the wagons (ill attempt to sell, for anyone reading this). I have a single one that is in 8/10 condition that I can use for measurements and design. When I get time Ill look more into it.

The wood jack stands are awesome. Better than ramps because they don't get in the way of doing work under the car (notice the set of metal ramps hanging up on the wall) and more safe than jack stands. Took some leftover lumber and screwed all the boards together when my father tore the deck of our pool out. Although they are a little heavy since they are made out of 2x6s. I think some holes could be drilled in the boards to make them a little bit lighter
 
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78Delta88

Master Mechanic
May 23, 2022
300
43
SW Arizona
I have a 3D printer and I've done a couple prints here and there, but I think bumper fillers would be out of my skill level for now. Although they are reproduced with an ABS plastic. But with 3D printing I also may look into attempting to 3D print the little plastic bolt caps that go on the wings for the wagons (ill attempt to sell, for anyone reading this). I have a single one that is in 8/10 condition that I can use for measurements and design. When I get time Ill look more into it.

The wood jack stands are awesome. Better than ramps because they don't get in the way of doing work under the car (notice the set of metal ramps hanging up on the wall) and more safe than jack stands. Took some leftover lumber and screwed all the boards together when my father tore the deck of our pool out. Although they are a little heavy since they are made out of 2x6s. I think some holes could be drilled in the boards to make them a little bit lighter
It's amazing how technology has come.
 
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Longroof79

Rocket Powered Basset Hound
Oct 14, 2008
11,667
113
Gainesville, Fl
As for locking the bumper shocks in place, you can always place a spot weld or two on the tube where it slides. Having tucked and narrowed bumpers, you're still taking a chance if you're hit or bumped. That's the risk we take. In other words, the bumpers won't provide much, if any protection. The way I see it. it's still better than those cheesy fiberglass roll pans.
 
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Longroof79

Rocket Powered Basset Hound
Oct 14, 2008
11,667
113
Gainesville, Fl
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64nailhead

Goat Herder
Supporting Member
Dec 1, 2014
4,819
113
Upstate NY
So for now ill be making a front air dam with something that can bend if I scrape on something. (Maybe garden edging)
I made mine out of a piece of 1.5 aluminum angle and two 1/4 fender flaps off from a big truck. I was about $30-40 invested and it works pretty well. I've scraped it once with no issues developing. It has to flexible, but not too flexible so that it doesn't fold at speed, but will push out of the way if it contacts the ground. I have a tube core support as well that I'm not anxious to have get bent because of it.
 
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Longroof79

Rocket Powered Basset Hound
Oct 14, 2008
11,667
113
Gainesville, Fl
Another thought on the airdam is using a flexible airdam/deflector off of an older S-10 or C-10? pickup.
 
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78Delta88

Master Mechanic
May 23, 2022
300
43
SW Arizona
I have a 3D printer and I've done a couple prints here and there, but I think bumper fillers would be out of my skill level for now. Although they are reproduced with an ABS plastic. But with 3D printing I also may look into attempting to 3D print the little plastic bolt caps that go on the wings for the wagons (ill attempt to sell, for anyone reading this)...
Good deal. It's amazing how all the Nickel and Dime stuff don't cost nickel or dimes any more. It could be nice little niche market for you.

A few years back I had the T-Bird Sport Decor Edition, with the leather straps that ran down the trunk lid. I couldn't find anyone available to make a reproduction. Only 708 made that year so good luck finding replacement parts for a 30 yr old car. I had to learn how to cast the pieces after making the silicone mold. Since then had to learn how to cast in plastic or metal, and how to electro-plate.

Technology keeps moving.
 
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