Group Buy/Interest Check: Rear Grille and LED Lights, Zero Decibel

[Mechie3]

Zero Decibel Motorsports Rear Grille


http://i.imgur.com/pYEsE0H.jpg
Prototype grille cleco'd in place

What:
Aluminum rear hexagon vent panel and multifunction LED lights. The grill can come bare (bond to inside of body, bolt on, or use rivets) or with flush mount PEM studs (threaded studs permanently pressed in that are flush with the outside surface).

Why:
The back of the 818 looks a little empty and plain. In particular the top portion looks like it is missing something. Exotic cars like Ferrari from the last generation (think F355, F360) used round hole mesh on their challenge trim level. Starting with the F430 a switch was made to a wire diamond mesh. This trend continued on with the F458. With the La Ferrari, Ferrari began to use honey comb mesh. Lamborghini was doing the same. Lamborghini dropped the wire diamond mesh from their entry level gallardo and switched to honeycomb on their new Huracan. The aventador also featured a honeycomb pattern. Mclaren used a hex extensively on the rear of their new P1 as well. Pagani dropped the wire mesh on the Zonda and went to a geometric pattern on the rear of the Huayra. Plain round hold mesh just seems so 1999.

Many low volume car makers are using Hella lights for the rear. I love these hella lights with their outside red ring and inside reverse and turn signal lights. I don't like the $900 price plus months of waiting to get a set. I spent a lot of time searching all over and found these affordable alternatives. Imported directly from a manufacturer in China they are ECE certified (EU version of SAE/DOT) sealed LED units. Unlike a lot of round LED lights, these don't look riced out or like they belong on the back of a semi trailer.

Although I have yet to prototype it, I have requests to make a lower grill portion with a matching pattern.

Cost:
This will be a partial group buy and partial interest check. The grills will be setup group buy style. The more people in, the better the price (though pricing doesn't get dramatically better like some parts I've had). The lights I can supply at any time. I do not get a volume discount on these so pricing is just set. I can order these on demand.

Bare Grill:
5 people: $105
6-10: $90
10+: $80

Add in pressed in flush mount PEM studs: $15 (at any group buy level)

Rear Lights:
$300 (includes two running/stop/turn lights and two stop/reverse lights)
Lights ship with flying leads (no connector).

Light mounting tabs:
$25 for 12

Shipping
Parts will ship flat and be quoted based on buyers zip code.


Mesh installed compared to cutout portion:
http://i.imgur.com/wws0duX.jpg

Running lights:
http://i.imgur.com/pMbqBQA.jpg

Brake Lights:
http://i.imgur.com/xyyCSnn.jpg

Turn Light:
http://i.imgur.com/2ovwEAP.jpg

Reverse Light:
http://i.imgur.com/JgWg2dk.jpg

Turn and Reverse:
http://i.imgur.com/AyWhPCq.jpg

[Mechie3]

Mounting Tabs:
http://i.imgur.com/Jg3f5cn.jpg

Details of the flush mount pem studs. If you have a hydraulic press you can buy them from Mcmaster (P/N 93580A220) and install them yourself with an arbor (a round piece of stock with a .140" hole and a slight chamfer). If you need them installed that $15 includes 20 of the pem studs pressed in.

Top view:
http://i.imgur.com/XVv0G9Y.jpg

Side View:
http://i.imgur.com/U65JDaK.jpg

When powdercoated or painted they should be barely visible. This allows you to mount the panels on the outside and hide any rough fiberglass cuts without seeing any hardware like screw heads or rivets. The inside uses standard 6-32 nylock nuts.

[Mechie3]

Here are the cars I used for my inspiration:

LaFerrari Exhaust Detail with Hex Pattern:
http://supercars.agent4stars.com/wp-content/uploads/2015/11/Red_Rosso-Laferrari-for-sale-exhaust-.png

Lamborghini with front Hex Pattern:
http://showautoreviews.com/wp-content/uploads/2013/04/Lamborghini-Aventador-LP-720-4-front-bumper.jpg

Pagani Huayra with hex and Hella lights (note similarity to sealed LED units):
http://images.caricos.com/p/pagani/2012_pagani_huayra/images/1920x1080/2012_pagani_huayra_9_1920x1080.jpg

Mclaren P1:
http://cdn2.autoexpress.co.uk/sites/autoexpressuk/files/styles/gallery_adv/public/mclaren-p1-6_0.jpg?itok=IfAvDhGF

[Hindsight]

Count me in for the works.

[Flamshackle]

really like it

[Ethan818]

I'm definately interested and like the change. However I'm curious how it would look with the license plate moved to the lower mesh area and the top section made with a single hex screen across the full width?

[Mechie3]

I could make a print out of it or even pay to have a one or two off made up. It's too big for the machine I have access too. I also milled it out (vs laser for production) and it took quite some time. That's one reason for making it a two piece. The other reason was I was going to put the license plate there (though, I have another idea for the exhaust now) and I considered making a third plate. All the parts I sell are made at a third party shop so I try to stock/make things that are mostly universal. If I had two guys that wanted it with the plate in the middle and two guys that want a full piece and two guys that want something else I lose volume pricing.

I'll try and get something tonight or tomorrow.

[Mechie3]

Would there be more interest in these if they fit the FFR lights?

[brian b 36]

Count me in on the works

[JAubin]

Would there be more interest in these if they fit the FFR lights?

Hey Craig, I have been thinking that I *might* be interested in exactly that setup....but I'm also interested in not expanding my budget anymore, heh. Would be inerested in seeing what it looks like tho, could you mock up the FFR lights in the existing panels easily?

[Mechie3]

I can set the lights on top of the panel. It's not a mesh panel, but a mesh pattern cut out of the panel so the rings the lights fit into are integral to the part. They can't be moved on existing parts.

[wleehendrick]

Would there be more interest in these if they fit the FFR lights?

Yes, I would probably be in for a mesh sized to the FFR lights with and a lower grille to match.

(macaroni extruders to complement all the cheese grater louvers I got ;))

[Mechie3]

What light positioning do you guys want? Same as FFR? Inverted? Red inside, white outside? Just the red (add your own white led bar somewhere else or mount FFR white somewhere else?

[07FIREBLADE]

Do you have any white led bars in mind that would work? Personally like the new style lamps they are brighter and more modern than the trailer lamps.

[Mechie3]

I didn't have any in mind because that wasn't the route I was taking. Just tossing ideas out there.

[JAubin]

Yeah I would be interested in seeing the FFR lights just sitting on the top of hte panels, Brake/Turn outside, Reverse inside maybe?

[07FIREBLADE]

Understand, do you think you could mock something up if I could get you dimensions or a template from harleys bumper with your new lights that you have found in place. FFR are just to RV trailerish for me now.

[Mechie3]

Yes. Get me dimensions or a template and I'll prototype something.

[THE FURNACE]

I would be interested in the complete set up. I never liked the tail lights. This would be a worthwhile improvement for me.

[SnyderJD]

I could make a print out of it or even pay to have a one or two off made up. It's too big for the machine I have access too. I also milled it out (vs laser for production) and it took quite some time. That's one reason for making it a two piece. The other reason was I was going to put the license plate there (though, I have another idea for the exhaust now) and I considered making a third plate. All the parts I sell are made at a third party shop so I try to stock/make things that are mostly universal. If I had two guys that wanted it with the plate in the middle and two guys that want a full piece and two guys that want something else I lose volume pricing.

I'll try and get something tonight or tomorrow.

I'm interested, but I would like to know more about what you are thinking with regard to the exhaust being tied in?

[Canadian818]

I'm interested, but I would like to know more about what you are thinking with regard to the exhaust being tied in?

Same here. I'm planning a centre top exhaust exit and would love it to be incorporated.

[Mechie3]

Been busy, haven't gotten back to this yet.

Exhaust: A third plate in the middle. For myself personally, I wanted to waterjet a carbon fiber piece. It would look simliar to the Pagani with the grill on the side and the exhaust having a different surround. Other options would be simple exhaust trim rings (customer provided), a grill that is similar with single round or double round cutouts similar to the light cutouts in the middle of the hex pattern. The only difficult part comes in that there are so many different options getting enough people to want the same one can be tricky.

I did manage to model up the full width grill and and a mock exhaust in solidworks that I can print out or share screen shots of.

[spaceywilly]

Love the mesh rear grille on the new Spyker C8. Reminded me of this thread

http://images.cdn.autocar.co.uk/sites/autocar.co.uk/files/styles/gallery_slide/public/images/car-reviews/first-drives/legacy/spyker14.jpg

[Mechie3]

Finished up some CAD models of different variations for the rear.

Plain full grille:
http://i.imgur.com/MAZcDNu.png

Full Grille with license plate in middle:
http://i.imgur.com/PjlriM7.png

Full Grille with round cutouts for dual exhaust (3" tips, 5" center to center)
http://i.imgur.com/1yrcSsh.png

Full Grille with oval cutout for dual exhaust
http://i.imgur.com/vHJoqaC.png

More than likely it would make the most sense to make a plain full grill and the end user can make cutouts for the exhaust and add a secondary trim bezel. It's unlikely that enough people will have or want the exact same setup. Since I order these from a shop I can't make 1 off's.

[Mechie3]

Split grille with license plate body mounted (real version of this shown in first post):
http://i.imgur.com/p85W9N2.png

Split grille with large center grille for exhaust:
http://i.imgur.com/8tCBnmF.png

Split grille with smaller center grllle for exhaust:
http://i.imgur.com/62aWSdG.png

Split grille with secondary round and oval trim rings added by user:
http://i.imgur.com/oVTzTdh.png

http://i.imgur.com/V3kfgdu.png

[THE FURNACE]

I still prefer the split grille with body mounted licence plate. If a separate center grille is offered, that might be the way to satisfy more builders.
Without a car, I have no idea about my options for running exhaust on an N/A engine. I'm hoping to exit somewhere in the bottom cutout, with equal length headers if possible.

[Ethan818]

I love the plain full grill. I would buy one of those if offered (and then mount the plate in the middle as shown in your second image).

To me it provides a cleaner look by eliminating the extra boarders/transitions and lines of the split grille option, that would otherwise be around the license plate or exhaust, but I do understand the practical/machining considerations.

[NBinSD]

I'd like an option for the full grill using the FFR lights and a matching trapezoidal grill for the bottom cut out.

[07FIREBLADE]

I personally like the split grill but Im in the Harley Vman style bumper category. So my opinion doesn't matter quite yet. I was wondering if you were able to draw something up with his dimensions yet so I could test fit the print out. I would love a matching bottom cutout and I could get you dimensions on that since I just got the bumper and prepping it for install.

[Mechie3]

I just made a cad model.last night for Harleys bumper.

[07FIREBLADE]

Where you able to get 2 large ones in or one small and large combo?

[THE FURNACE]

A third vote for the matching lower grille. If voting favored the full upper grille, it might look better if the top was arched to follow the body line, like the Spyker C8.
It will be difficult to change my mind for the split grille and body mounted plate though. Stubborn Italians!

[Mechie3]

Well, it took me long enough. Paper test fit of the lower trapezoidal grill. Going to have this quoted soon. Also posted a pic of similar grille styles that I made for the Harley style rear bumper. Once they're all quoted I'll probably start a new thread with all of the available types with pricing. All of the grills are mounted using flush pem studs and have the same hex pattern.

http://i.imgur.com/jowpavM.jpg

http://i.imgur.com/rMg733V.jpg

[Xusia]

Hey Mechie! I love the idea of a grill for the lower area - the hex pattern looks great! I'm using the diffuser and was just planning to leave that space open (it was just too plain without a cutout or SOMETHING), but I like your grill, so thanks. I look forward to seeing the final product/design. :)

[metros]

I'm in for the lower trapezoid (Factory Five Bumper) and rectangle specs we discussed via email previously. Let me know when you're ready to put the order in and what I owe you.

[DMC7492]

Hi Craig, Im in for the
trapezoidal lower grille.
This upper rear grill 62747
And the LED rear led lamps
With PEMS on both
Thanks Don!

[STimedic]

Craig, I'd like to do the diagonal upper setup with staggered light sizes, what's the projected cost on those for reference?

[Mechie3]

I have to get the full width rear quoted as well as the diagonal ones.

[07FIREBLADE]

Were you able to make a set of mounting tabs for your lights yet mechie? I've got some made from scrap aluminum that i had laying around but some nice laser cut ones would be preferred if you have them.

NVM saw an earlier post you finally had them made. Can I get set from you.

[DMC7492]

Craig, what is the diameter of the light holes for the four similar size lights?

[Mechie3]

3.5" hole opening.

[Mechie3]

Made a paper template of the full size upper grille and test fit it last night. Leaves a .1" border around the perimeter for better fitment. It's out for quote, waiting to get it back. Also modified the light mounting tabs to make them a little less boring looking. Waiting for the quote on those too.

http://i.imgur.com/HpoO8T3.jpg

[Mechie3]

Pricing for the full size rear grille is as follows:

1 person: $215
2 People: $180
3 People: $150

This includes the above grille with 18 pems pressed in and nylock nuts to mount it. Does not work with FFR supplied lights. Will work with 3.5" lights (or the opening can be sanded open for a slightly larger light).

[brian b 36]

http://i.imgur.com/p85W9N2.png like this one with lower grill to match

[Mechie3]

http://i.imgur.com/p85W9N2.png like this one with lower grill to match

Any body else interested in a setup like this before I place an order? My prototype parts are going to "The Furnace" in Canada. I'm revising the price of the lights down from $300 to $275 as well. Lights are not DOT, but are E-marked (EC/ECE, European DOT equivalent).

[Mechie3]

I have ten sets of the grille shown in the post above this now. Need to sand and press in pems.

[Mechie3]

Test fit of the first full size grille (didn't cut out the rest of the bumper for the pic). These are new lights. Bigger than the previous lights and, best part, these are DOT marked for legal compliance.

http://i.imgur.com/g570meM.jpg

[BrianToronto]

Powder coat those grills and its one of the nicest rear ends I've seen!

[Mechie3]

Don currently has the only one of these out there so we'll have to see what he does with it. 07 Fireblade has a similar rear end that he powdercoated black (his is in three sections vs the 1).

[DMC7492]

Here is the full rear grill from Zero Decibel! All I can say is Craig is very cooperative and honest!! The install is no where being complete as the finish work is far away, did not receive a no paint finish! I agree a black finish on a light car will look killer!
69647
69648

[brian b 36]

Craig thought I would post the finished product 6980869809 thanks Brian

[DMC7492]

Looks good Brian!! I like the side marker lights, I have been looking at every vehicle on the road to find a nice looking one. What are your from?

[fastzrex]

Craig thought I would post the finished product thanks Brian

Well done!

[brian b 36]

side marker lights are out of a 97-01 crv its nice having a salvage yard I walked through and took 10 or so home and did it again till I found what I needed

[Mechie3]

Sweet! I like how that looks. Thanks for posting the pics!

[Mulry]

Craig, I'm interested in the setup like Don has. Not sure about the lights yet, but the grilles at least.

Pat