Hey everyone,
I searched around for a good skidplate how to, and the best bit of info I could find was this diagram (which I put to good use):
This skidplate is a radically different shape than the stock dust cover and it does a great job of protecting crucial parts and has an awesome fitting as well. Kudos to whoever created our diagram.
First, I mocked up a cardboard template with these dimensions to test for fitment. I bolted the cardboard sheet under my car and marked the location of all 5 bolt holes. I had accidentally held the cardboard up slighlty crooked and so my bolt holes were at first crooked as well, but the overall fitment was great so I moved onto the next step.
I marked out the same diagram onto a sheet of 1/8" aluminium and then traced the approximiate locations of bolt holes from my cardboard template. Using these hole marks as a rough guide, I then refined their location by using a tape measure to ensure that everything was straight and in line making sure my skidplate would bolt up straight.
The next step was to cut out my aluminium skidplate. I'm lucky enough to have access to a plasma cutter (which worked awesome), but you can use whatever you have available to you. I then bevelled the edges with an angle grinder and touched up any sharp bits etc. etc. The details are up to you.
Finally, I used a hydraulic press and some bits of angle-iron to bend my front and back edges. All that was left was to drill the bolt holes; I used the largest drill bit I had on hand to allow for maximum wiggle room when bolting the skidplate into its new home. I used a 1/2" bit and rounded the holes out further by rotating my drill on an angle to allow for the largest possible hole size.
I fixed the skidplate under my car and everything looks great. I would recommend this to anybody considering an expensive after-market skidplate if you have access to basic tools and machinery. The entire process took about 2+ hours and because I was able to score my aluminium for free, my total cost was $0.00.
As an aside, I priced out aluminium for this project and it was something like $150 for the square footage I needed. Not much of a bargain compared to $200 for a pre-fabricated skidplate. But, if you can find some cheap scrap aluminium like I did, go for it. It was a breeze.
Pictures:
Lining up the cardboard templateCutting out the actual plate (bagged lunch pictured)Skidplate things are coming togetherBent edges, drilled holesReady for installInstalled & FitmentFeel free to cut out whatever oil change or speed holes you think are necessary. Enjoy!
PS: 1 plastic WRX under carriage dust cover for sale. Nearly-good condition. $50.00