In this stage of the StealthBuilt Audi A6 Widebody Project, Sam Kimmel and the Kimmel Fabrication Studio take on the task of designing the rear spoiler mount. As with the rest of the build, the goal is to prototype, experiment, and refine through a hands-on, cost-effective process that encourages creativity without breaking the bank.
Starting with a Strong Foundation: Spoiler Positioning Framework
To visualize different mounting solutions, Sam and Roger build a simple 2×4 mock-up frame. This allows them to:
- Hold the spoiler in a consistent position
- Test both chassis-mounted and trunk-mounted designs
- Stand back and assess aesthetics and alignment from all angles
It’s a prime example of the “mock it before you machine it” philosophy that defines this entire build.
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Laser Level vs. Plumb Line: DIY Vertical Alignment
TPrecision matters when mounting aerodynamic parts like spoilers. To achieve vertical alignment:
- A laser level is used for high accuracy
- But Sam shows a budget alternative using a string with nuts as a DIY plumb bob
“You don’t need an expensive laser machine—just some string and a weight gets you the same vertical line.”
This tip underscores the DIY spirit of the project, helping others replicate it with basic tools.
Cardboard Templates and False Mounts for Visualization
To test visual concepts, Sam uses large sheets of cardboard to:
- Create a chassis-style mount illusion
- Cut bumper profiles using a profile gauge
- Fabricate cutouts and simulate how the spoiler would appear bolted through the bumper
This process helps:
- Avoid wasting material or committing too early to a design
- Evaluate aesthetics
- Get precise shape matching using hands-on methods
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Testing the Trunk-Mount Gooseneck Design
After evaluating the chassis mount, Sam builds a Gooseneck trunk mount mock-up. The team then:
- Shares both designs with the community on TikTok and Instagram
- Lets the audience vote on which design fits best
Surprisingly, the trunk mount wins by popular vote. Its smoother flow with the car’s body lines makes it the favorite, even though Sam originally preferred the chassis style.
CAD to Cardboard: Testing the Digital Design Physically
Once the design is finalized, it’s converted into CAD drawings, but before sending it to the CNC shop:
- Sam prints the full-size CAD drawings
- Adheres them to cardboard with spray adhesive
- Cuts the template to test fit on the car and spoiler
This step bridges the gap between digital design and physical accuracy, ensuring perfect fitment before machining it in aluminum.
“I wanted to make sure it actually fit the way I wanted before sending it out to be machined.”
Key Fabrication Takeaways from Part 8
Use low-cost materials like cardboard to prototype expensive parts
Leverage community feedback for final design decisions
Don’t skip full-scale physical testing of CAD models
Explore both form and function before committing to fabrication
Community-Driven Build, One Vote at a Time
The success of this build lies not just in its craftsmanship but also in its collaborative nature. Sam regularly polls followers for design input, turning a solo project into an interactive experience that blends automotive engineering and social media engagement.
Watch the Build and Follow the Journey
📺 Watch the full spoiler design video on YouTube
📸 Follow us on Instagram and TikTok: @stealthbuilt
💬 Have questions or want to share your own build ideas? Drop them in the comments — Sam often replies directly or includes them in future updates.
