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Old 09-23-2008, 01:46 PM   #1
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Exclamation My Kammback'ed VX

So this past weekend a buddy and I had a chance to try making a Kammback for my 94 VX. I wanted to make it out of Plexiglas so as to not restrict rearward vision.

I'm no expert when it comes to working with Polycarbonate glass, so don't expect a miracle product on the first run, lol.

Here is the profile shot:


Here is the profile from the rear:


Please excuse the Cell phone pictures for now. I haven't had the time to take a proper picture of my work.

A loose how-to:
  1. Lay down cardboard and trim to desired shape on the car
  2. Transfer cardboard shape over to the piece of plexi
  3. Use a straight edge or a guide that follows your trace and score the plexi with a sharp razor knife over and over
  4. Lay the groove on the edge of a table and place a square tube or two-by-four on the edge and clamp the two-by-four to the table
  5. Gently start to rock the plexi downward in order to get the groove to crack (it helps to have two people for the this part if it's a long piece. You could even take two more two-by-fours and place them on top and bottom close to the groove to assist in breaking the plexi cleanly)
  6. Once you've snapped the shape out of the plexi, center and attach the piece to the top of the car
  7. I then used two pieces of flat metal stock and clamped them along the area that I wanted to shape to the curve of the car (coming off of the hatch area to behind the car)
  8. Use a heat gun (best) or a propane torch (careful to not melt the plexi) to warm up the plexi and soften it
  9. Once it is soft, form it to the angle that you desire and temporarily tape it in place
  10. Repeat for the other side
  11. Use screws or industrial adhesive to attach the plexi along the rear spoiler
  12. Attach the sides in a fashion that you see fit. I am using Gaffer's Tape for a temporary time

I am holding the sides tight to the car with Gaffers' tape at the moment as I still need to fab up some nice aluminum brackets that mount the the lift shocks on the hatch glass to hold the sides tight.

The tape is holding amazingly well after already going through rain, both at city street speeds and highway speeds up to 70MPH.

Constructive criticism and comments are welcome. I'm already hearing from my wife and friend's wife that it looks funny and they wouldn't want to ride in the car now, lol.

Thanks
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Old 09-23-2008, 01:52 PM   #2
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Tom, looks really good! It looks better than anything I've seen to date. A more permanent mounting solution would be nice, but as long as it's secure who cares? It seems much better than cardboard or fiberglass options.
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Old 09-23-2008, 02:17 PM   #3
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Its great to have you back on the forum Tomo.

Since the VX is a hatchback, I always wanted to know if a kammback would boost the VX mpg.

I'm really waiting for those mpg number with it on. Also, the visibility thing is quite important too.

The result look good and interesting for the FE! And what is the price of the project (Polycarbonate glass)?
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Old 09-23-2008, 02:26 PM   #4
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Yeah where'd you pick up the plexiglass? And I've heard others mention Gaffer's tape, sounds like it holds really well and looks much cleaner than duct tape. Can you just find that at any hardware store ?
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Old 09-23-2008, 03:05 PM   #5
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Yeah where'd you pick up the plexiglass? And I've heard others mention Gaffer's tape, sounds like it holds really well and looks much cleaner than duct tape. Can you just find that at any hardware store ?
Try a music store like Guitar Center. It is used a lot on stages. I just picked up a roll two weeks ago form GC. Home depot or Lowes may carry it as well.
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Old 09-23-2008, 03:27 PM   #6
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itjstagame: You thinking of kamming your truck? I've toyed with the idea, but figured there were other mods to do first. I am trying to make my truck appear as unmodded as possible to the untrained eye.

-Jay
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Old 09-23-2008, 07:36 PM   #7
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No, the truck will get a fastback type cover eventually. But I was planning to use Gaffer's tape everywhere I can, the duct tape makes a mess and doesn't last.

As for the plexi, was thinking about lots of aero uses, probably on the Festy.
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Old 09-24-2008, 07:41 AM   #8
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Quote:
Originally Posted by hondaguy72 View Post
Tom, looks really good! It looks better than anything I've seen to date. A more permanent mounting solution would be nice, but as long as it's secure who cares? It seems much better than cardboard or fiberglass options.
Thanks! I was thinking of using Coroplast, but Plexi is see through. I don't even notice it in the rearview, although Coroplast wouldn't be a huge hindrance with the angle of everything. But this way my third brake light is still visible to traffic.

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Its great to have you back on the forum Tomo.
Thanks, BIBI, I've actually been around a bit but haven't had much to contribute lately.
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And what is the price of the project (Polycarbonate glass)?
I got a sheet of 1/8" 4' x 8' Polycarbonate glass for free as it was laying around at my parents' cabin. I would check your local home improvement stores to see what they want for a sheet. I only used half of the sheet for this project.

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And I've heard others mention Gaffer's tape, sounds like it holds really well and looks much cleaner than duct tape.
Be prepared to spend nearly $15 or more for a roll of it though. It's strong stuff and tears straight and easily off of the roll.
Unfortunately, a severe rainstorm got a hold of the tape last night and loosened up some of it a little bit. That was only on the side that has a little more tension on it from the edges of the plexi though.
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Old 09-27-2008, 09:29 PM   #9
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Just for the record, Plexiglas/acrylic is not the same as Lexan/polycarbonate. The latter is far more durable to impact and scratches, though more difficult to work. I strongly recommend that any permanent final solution be made of polycarbonate.
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