Designing FT-1 inspired wing- Looking to see if there is demand as well as suggestions for improvement

[TheMaker]

After that first print, I immediately noticed some things I could change so i did.

The overall thickness of the deck made the channels for the cf rods to be placed awkwardly. in order to give them more space for better positioning, I scaled the height of the deck by 12% and the span by 3.5%. In the grey/ gunmetal photos you can see how the slight increase in height gives the wing more of a "scoop" as the light reflects of the area. I like that visual separation because its still smooth but adds a stronger transition upward.

With the new position of the rods within the structure, I noticed the tolerance between the rod and the print was too tight. I added and extra 0.1mm and made a little test print to see how it fits. Bang on this time.

I added an additional 2 holes for the deck mounts, 3 before vs 5 now. The mount itself is a bit more low profile as well. With the idea of it being CNC'd, i decided to take out some bulk. I did the same for the bottom mounts but they look generally the same. The only change to the bottoms that still needs to be made is adding the through-holes for the trunk and under trunk brace/support.

Aside from these changes... I think this is it. I've stared at/ thought about this design all day thinking what I could change but nothing really came to mind. The riser (for a shorty version), endplates and potentially a gurney flap can be modded but the fundamental design is likely to stay as is.

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[TheMaker]

While the full FT-1 concept wing is printing, I decided to make a shorty version.

Everything fits the same, except of course the shorter riser/ uprights

The deck is different.... shorter chord with a slightly elongated middle section (this would fit the full size spoiler setup as well)

It is 85mm shorter

 

[TheMaker]

Had a few print failures and basically needed to start the printing process from scratch. The first print came out nice but it was heavy af… im reducing the walls to 4 as well as the infill to provide internal structure… with a 0.8mm nozzle and 0.9mm line width, thats roughly 3.6-4mm wall thicknesses all around.

Added a gurney flap as well, 8mm tall so its not too crazy for the street, taller ones are also doable.

Increased the height of the endplates as well, the shorter ones now go with the shorty risers, though both will fit both styles

 

[3literV8Eater]

When this design is ready for retail sale/group buy, I’m going to have to pull the trigger on one. There’s nothing like something original not everybody will have and looks awesome.

 

[TheMaker]

When this design is ready for retail sale/group buy, I’m going to have to pull the trigger on one. There’s nothing like something original not everybody will have and looks awesome.

Thanks man, its comments like that which make me want to push harder for this.

Im currently looking to buy a used trunk to test fit and im making small tweaks here n there, hardly noticeable things but they make sense design-wise.

Theres a lot of things right now that i have to do on my own before i can get to the higher stages of this project where im going to need help so progress is slow but moving forward.

its a long process but im enjoying every step

 

[overdrive25]

After that first print, I immediately noticed some things I could change so i did.

The overall thickness of the deck made the channels for the cf rods to be placed awkwardly. in order to give them more space for better positioning, I scaled the height of the deck by 12% and the span by 3.5%. In the grey/ gunmetal photos you can see how the slight increase in height gives the wing more of a "scoop" as the light reflects of the area. I like that visual separation because its still smooth but adds a stronger transition upward.

With the new position of the rods within the structure, I noticed the tolerance between the rod and the print was too tight. I added and extra 0.1mm and made a little test print to see how it fits. Bang on this time.

I added an additional 2 holes for the deck mounts, 3 before vs 5 now. The mount itself is a bit more low profile as well. With the idea of it being CNC'd, i decided to take out some bulk. I did the same for the bottom mounts but they look generally the same. The only change to the bottoms that still needs to be made is adding the through-holes for the trunk and under trunk brace/support.

Aside from these changes... I think this is it. I've stared at/ thought about this design all day thinking what I could change but nothing really came to mind. The riser (for a shorty version), endplates and potentially a gurney flap can be modded but the fundamental design is likely to stay as is.

Is there anything that could be done to prevent having drill holes on the top face of the wing? It would look much better with a flush top in my opinion.

 

[ericchen_ec]

Thats not a bad idea the only thing is that i would need one their wings and mounts to get the bolt holes to line up. Its actually kind of harder to retro fit to an existing product than to create it yourself, in terms alignment anyway. Im not opposed to the interchangeability and I dont see that as "copying someones work" because I'd be making original designs, they would just be mounted in the same locations.

I wouldnt worry about having to redesign the uprights to fit the verus mounts, Its fairly simple I could do it for any mount

I might reach out to Verus and inquire this with them. Worst they can say is No.

I was contemplating just buying the trunk skin from a local dealer and using that as mock-up. I could buy various mounts from different style existing wings and make my own retro-fits. I wouldnt be competing with any of these manufactures either because the supra owner would likely have that companies wing first as a dedicated track wing... mine second

If I'm understanding correctly

i actually might have a pair of trunk mounts for the verus ucw in my garage, i can look for it if you're interested lol

 

[TheMaker]

Is there anything that could be done to prevent having drill holes on the top face of the wing? It would look much better with a flush top in my opinion.

the original concept was to have the deck printed and bonded with internal rod supports. After the t-nut is inserted on top, it can be filled, primed and painted for a smooth finish.

I haven’t gotten around to it yet because right now my primary concern is fitment… but ill be redesigning the top deck for cf manufacturing. There wont be a need for the top holes in this case.

I like this option better because it takes the huge task of manufacturing off my hands (i don’t work in a shop), I don’t have to work 2 full time jobs, and you guys get a much better looking product.

 

[TheMaker]

i actually might have a pair of trunk mounts for the verus ucw in my garage, i can look for it if you're interested lol

in order to test fit and work off a better scan… i decided to purchase a trunk lol

From the looks of it, it already had a verus wing on it before the owner crashed it. Wing not included unfortunately, but i got a sick deal on it because they considered the drill holes as damage, which ironically is exactly what I needed lol

if i need them ill let you know, but i should be able to get all the geometry i need from the trunk.

UPDATE: trunk bought. I should have it this weekend

 

[TheMaker]

More visuals, no real update.

I should have the trunk and ill be making a scan of that. I dont know if anyone is interested in seeing parts of that process but ill document some of it.

With the trunk mount holes already in place, it really take a lot guess work out of the process which im relieved about lol.

Update: Started the redesign to CF/ GF construction. It definitely looks cleaner without the pass-through holes for mounting.

 

[TheMaker]

In possession… ill be scanning soon

As it stands now, my trunk mounts might not cover the last hole near the bottom of the trunk.

Would this be a big deal if it were to be just plugged or would you guys want the mount modified and extended to use the hole?

Its no big deal to modify, just gauging how you guys feel about this detail

UPDATE: might be able to make it work if i move the entire structure back 25mm, though its there's an awkward gap. Last photo, front of the mount relative to trunk edge. By lengthening the mount, it reduced the awkwardness and covers all holes. Ill add pockets on the underside to remove an excess material to keep weight down. That solid part in 6061 would be bricky. Last 2 photos are updated, extended and moved back.


*** Before workflow was more based around creating the shape organically. As of now Im focused on making the components CNC and production friendly. This will bring down costs overall with very little to aesthetic compromise

 

[TheMaker]

Life's been a bit busy lately so I havent been doing much to push forward in the on the design but I have been looking into manufacturing more just to get an idea of what that might look like.

Ive also been trying to get OpenFOAM to work to check the wings in CFD. Not successful yet but im working out the bugs. I've never coded before but ChatGPT and youtube are very helpful. If anyone here has any experience or knowledge theyd like to share on this program im open

Still need to 3d scan the trunk and translate the mounting whole and design support under-brackets.

What I did do is a slight redesign with a NACA 12-512 profile wing (slightly scaled to fit my desired size) 1325mm span, 275mm chord, 6mm integrated gurney. Let me know which version you guys prefer ill post 3 pics of the OG wing, we'll call it V1 and this new one V2 (Blueish wing is V1, grey with yellowish lighting is V2 NEW)

*** V2 does not have wing mounts yet

 

[samurai_sony]

it looks amazing

 

[TheMaker]

it looks amazing

Thanks man! More to come I’ve just been really busy with work but I’ve been working on this in the background.


Decided not to print anything because Ive had to make improvements here n there but it’s like 85% there design wise. Hoping to have a final printed prototype soon

 

[TheMaker]

Really proud of this upper mount. Looks great imho and adds just enough shape and detail that it sets apart. This mount has taken me like 20 versions and attempts, no exaggeration...it only looks too thin at the mounting surface because it rests in a slight recess, its 5mm thick, 6mm thick where it bolts to the riser… cf composite. If cf is too expensive/complicated, ill just thicken it and cnc aluminum

Thinking about tge way theyll be mounted to the wing itself, I put up some examples of how other manufacturers have done it… carbon fiber bracket, high strength blind rivets (8x per bracket, each as a holding capacity of 800lbs tensile strength) and a structural epoxy adhesive.

Base AoA is 6 deg, then 8.5 and 11 deg

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