Deflector Part 2

Just a quick one as I do not want to give away too much.  Finally managed to do up the fibre glass work with Chooped Mat and Roving.  The Roving is better suited to hold the surface on the edges as it is stronger.


Producing the top surface Needed to brace this securely on this working design.  I would not need to get a really solid grip on the production model as it will totally be fibre glass.  As it is now, wood is used as the main structural material.  I would only need this working design to make some sets of mould.  The finished product would therefore be much lighter and look nice.

Deflector mounted on car

Deflector mounted on car

Had a spin around Putrajaya.  About 45km distance.  First round registered 4.3 l/100km while the second registered 4.5l/100km.  Will keep doing test and maybe try to add more surface area on the bottom.  I am very happy as it is, there was little effort to try and clean it up.  Not even fillers and it still meets the target.  Probably I might get better results with the extension.


Adjustable Spoilers Part 2

It has been a few weeks of browsing through my den of broken things to put together a test rig.  The reason being to please my self doubt about what I am trying to do.  A lot of times I have questions floating in my head if I could actually pull this off.  I have been messing around on the internet and trying to find something that could show that my half baked ideas is actually worth the time.  Time is on my side.  I have stopped working for the moment.  I ended my previous job as a Manager for Fire and Gas Detection system with Draeger Safety with a small compensation package.  That bit of kit would probably last me a few months before I actually need to find a job.  At 45 years of age, that is not going to be easy.

I have taken a piece of wood from my hoardings and bought a cheap set of planer.  The last time I used this was in Secondary School in the early 80’s where we learned woodworking.  I therefore whittled down this piece of wood for two days to come as close as possible to the profile that I needed.  I also used my dremel and coarse grit sandpaper to give a good smooth finish.  Woodworking is very addictive I must say.  I find myself constantly reshaping the profile untul it looked satisfying to my eyes.  I was not looking for an effective aerodynamic profile.  I wanted it to look good.  I had to force myself to stop because I needed to do this rig and reassure myself.

I took the finished piece of wood and proceeded to find the center of gravity.  This is crucial as this would help to reduce the torque demand on the servo motor.  Placing the servo in line with the axis of rotation means reducing the weight that had to be moved around the axis.  I simply held the spoiler by the side of both hands.  I slide both hands to the center of the piece.  Where the tilted, the weight has gone the other way.  I slid the hand which had no resistance because of this shift.  I put the wood on a pen and tried to balance it as much as possible.  This way, I found the center of gravity and marked with a pen.  I then used the grain of the wood to show me the pivot point at each end of the piece.

Then I looked inside the cabin again to find unused TV stands meant for my 42 in plasma TV.  I drilled both at an approximate height.  The undriven pivot side was held by a simple screw.  The driven side had a servo hub which was nailed.  The hub has a 24T spline which would normally be attached to the servo shaft and screwed in place.  This is another issue that I would need to address.  I would need to cut an approximate width of 20mm to enable the screw to tighten the sawn wooden piece against the servo.  Once that servo is tightened, it would then be screwed to the main piece.


Finished Test Rig

I have been trawling the pages of Servo City for a few weeks now and have ordered some bits and pieces.  I will tell why I need those a few paragraphs later.  I have made a test rig to show myself that the small servo could turn the wooden spoiler.  A video of which can be found on my facebook link here


Close up of Hitec HS-425BB RC Servo

What I have realized after playing with the test rig is that the weak link lies in the connection to the HITEC Servo.  This HITEC HS 425BB was bought from a local Arduino authorised agent at  It was the biggest RC Servo that they had.  I could see that at a speed of 200km/h and with a surface area of 7,500mm2, the wind load on the spoiler would only be contained by the servo hub and the swivel joint.  Even though this HS 425BB is a model with bearings, I would think that it would not be sufficient to handle the load. Therefore I decided a redesign is in order.  Part of the items I hard ordered online was an aluminium arm to connect to the spoiler.  But because the spoiler would have a different pivot point and than the servo, the hole on the arm must be modified to a slot.

Having two support on the driven side would increase load capability.  This also means is that the torque demand on the servo would be increased.  I am prepared to make the spoiler lighter by hollowing; making more holes where necessary.


Secondary Intake Pt 3

At the end of this project, I remembered when I was roughly 12 years of age, I was into making model spaceships.  I had picked up a magazine about Scratch Building.  Initially it was to make a diorama for my scale models.  But it grew on to making a complete spaceship out of two aluminium cans and one plastic cap.  The cap became the engine exhaust.  I had painted it white and took a picture of it with black paper as the background.   That was my experience with working with house hold items.

View of internal of air scoop.

What air would see before being sucked

I wanted to cap off this project with something spectacular.  But then I kept reminding myself of the reason why I did this.  It is to make things as simple as can be.  Hopefully it would inspire ordinary men on the streets to come out with their own ideas in increasing efficiencies of anything they have.  All the items I used can be bought from the nearest hardware store.  Even the tools; which is a knife.  That is the beauty of science; it does not limit to rich people, it does not want to burden people.  In fact it enlightens to those who seek it.  It does not provide the glitzy glamour of a high priced premium aftermarket which endears the modding community here.  But it does save money for the rest of the working people.  If they could only open their eyes to possibilities.

I decided to increase the intake are of the flexible pipe by having a scoop.

Recycle Reuse Reborn

If you are like me, I have a shed which I keep all chemicals, paint, thinner and lubes stored on the top shelf.  I had a small bottle of Automatic Transmission Oil which is quarter full.  The shape of the bottle was interesting.  It had a sloping line before it meets the cap.  It also had different radiuses as its edge.  This was significant to meeting my requirement.  The hole where I inserted the front end of the intake has a matching shape.  When I tried it on it was a perfect match.

I had to cut the hose further as the bottle will be using up the length.  I inserted into the bottle’s neck and taped it with Electrical Tape.  I then inserted this below the headlight cluster and left it there.  It fit snugly and there was no need to tie down the white hose further.

While feeling satisfied at how the project turned out, one can never truly be complacent.  What was very apparent from the beginning was that I was toying with household items which others never think of being an engineered product.  What may be difficult to find 10 years ago, has become common and the price of these have gone down.  While I would be most challenged to make a purpose built equipment, nothing beats simplicity.  This mod project truly embodies the reason for this blog.  Anyone could do this project.  He doesn’t need to have an AutomotiveFits nice and snug

Engineering degree.  Its just a matter of wanting and how bad you want it.
Tonight I took the family out to take an opportunity to test the set up with full load.  It was satisfactory.  “Sorry bout that Mr. CR-Z! I’m doing an experiment!”


I am just about finished with this project.  Even though its a relatively short testing period, I am well convinced that it has met its objective.  The objective was to reduce average fuel consumption.  The method is not new but I believe it is for this Proton model.  People may think that just because it works for a highly engineered product that it will not work on others.  They are well and truly misjudging its benefit and impact.  An engine in an old car is still an engine in a new one.  The fundamentals remain the same.  I have now increased the fuel efficiency of the car by 30% in Highway mode.  It should reflect a fuel saving of not less than 20% on average through the entire journey.  But I seriously doubt  it could improve the FC during idling.  That is a project to be done in another day.  I look forward to working with others on a similar project.