speed43

I want to make a spoiler for the trunk for the W202's. Will be made from fiberglass. Quality will be real good and will ship either in primer or painted and clear coated. Up to the customer.

I would like to ask you guys what style would you suggest? I won't make crazy looking ones. I was thinking to make one like the C55 amg. And to make it fit way back to almost touch the Mercedes star in the trunk. Most rubber spoilers sit flat on top and are to short at the side ends. I don't really like that.

I want it to HUG the trunk like if it was part of the trunk. It will have 3M double sided tape so no holes will be needed.

Any opinions?

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ECTurboGSX

I've always been a fan of this one, which I believe was originally styled by Carlsson: https://spoilernation.com/1994-2000-...p-spoiler.html

I would recommend taking a look at the EX family of foam core tapes from 3M. One mistake that is easy to make is that on foam core tapes, you need to leave a gap around the perimeter of the spoiler for the tape to be compressed during install, generally at least 30-50% of the tape thickness. EX4011 is 1.14 mm thick, so you generally want to leave a gap around the spoiler of ~0.5 mm. You'll then want to press with around 30N (~7 pounds) per cm2 during install. There are other thicknesses available in the EX line and you want to select your thickness based on how much variation you expect to see spoiler to spoiler and trunk lid to trunk lid. Thicker tapes let you handle more variation but then you need to also run a larger gap to get good compression and wet-out. If done properly, the EX tapes will not come off unless you cut them off with something like strong dental floss. Good luck and looking forward to seeing the finished product!

brad_c43

Ive got at least two votes for this wing

DRBC43AMG

Rear spoiler from AMG parts catalogue
I would remain with the original AMG look. It goes so much better with the period era of the w202 IMO. Photo taken from the parts catalogue I had on hand some time ago. Apparently it came in two versions: with/without third brake light

mickey13

yeah from a business standpoint, because you want to sell these things. you should make something that is currently unavailable elsewhere. sticking to the original AMG design would be highly desirable if it is no longer available.

silverc4s

ECTurboGSX

The style this is posted above is going to have to be bolted on. That isn't enough of a joint to use double sided tape. Going with a lip spoiler, similar to the one I posted above or to the one that comes factory on the W203 C55 can be done very easily with tape, so no drill templates, drilling holes in your trunk lid, water leaks, rusting, etc. The OEM W202 spoiler is also a much more complex spoiler to make at home or even for a prototype shop. You'd need split cavity tooling and an expandable bladder in the core to make that shape or you have to make it in two halves and bond it together, both more complex than a lip spoiler.

speed43

Thanks guys for your comments.
i want to make one that does not require making holes as ECTurboGSX mentioned.

And thanks ECTurboGSX for the info on the tape. I know what I want now just have to make the time and buy a trunk so I don't mess mine up...

DRBC43AMG

I guess you can find any W202 trunk from the scrap yard to use as your template. I don't think they are any base differences between models in the w202 family

speed43

Hard in Chicago but I'm going to keep looking. Won't be doing this spoiler soon. Need to make some air boxes in advance and put them on eBay. Than I can start on this new project.

ECTurboGSX

No problem. This is my baby, so I've got spoiler design fresh on my mind :-) I can't say this with 100% confidence, but I do remember reading that the trunk profile is slightly different on the 95-97 W202 vs the 98-00 W202. May be worth double checking.

speed43

Close to what I was thinking. Check it out.

ECTurboGSX

The outer shell is easy enough. You'll need to figure out how you want to do the surface that bonds to the trunk. Easiest and cheapest is probably a polyurethane foam fill. You could also fiberglass up a second piece that matches the trunk lid with flanges at the top and bottom and glue it in. The Tesla spoiler is made that way, with separate inner and outer carbon fiber pieces bonded together. Are you shaping a master and then making a fiberglass tool around it or cutting out RenShape to make the tools?