A wing that's 3D printed + fiberglass work

Hello! Here to share a project i spent months on a couple years ago that started as a joke, which ended up being a successful end result. I'll share my process from beginning to end. I didn't take much pictures in the beginning as i didn't think i would be commited to the idea.

This spoiler was completely made from scratch using Autodesk Fusion 360 (Which took me forever to learn how to use) , and inspired by the Garage Saurus wing which in contrast sits lower and further back more like a drag wing. No scans and a lot of trial and error

I designed the deck, ends, and base seperately as it would be much easier to print and for me to design (I had no idea what i was doing but with the help of youtube i managed to get what i envisioned)

To keep things light, I tried to print it with zero infill and i would drill a hole in each one and fill it with expanding foam. But the zero infill prints were usuccessful because the prints would warp inwards during the heat to cooldown phase. So I printed it with 1% infill and that was enought to keep the print straight.

26 prints later I plastic weld everything together and end up with this. I fill each piece that i would with expanding form to help keep the plastic from collapsing over time.

Now the hard part. Which took me months and lots of patience. I start the process of laying fiberglass over it and constantly test fitting to make sure it lays on my trunk right. I started with chopped fiberglass because it would be easier to conform to all the edges and corners better. I do 2 layers of this

Then i add 2 layers of fiberglass cloth mesh. This was much much harder to conform. I do my best to make these layers as smooth as possible to lessen the amount of filler work i have to do.

 Lots of tedious bondo work to make it perfectly straight.

Then the satisfying part to see how all that work has turned out. Primer

Then the best part. Paint.

End result

I had this wing on for about a year and a half before i did my visual overhaul on the car. Driving through hot summers and the cool fall, on highways and some street driving, it held up with zero issues. I had built in studs with washers in the wing, and double sided tape to keep it mounted to the trunk.

Would I do it again? Probably never, it was way too much work. But for my first time doing something like this, it was worth the experience.

Would be happy to help answer any questions for anyone doing the same thing!