Make a set of front and rear paper templates; we simply traced the outline of the inside lower portion of the front fender well and the rear lower of the side skirt. The side skirt has a recess in it that provides the shape of the gluing surface, on the fender well we used a 1 inch high gluing surface.
Transfer the shape of the paper templates to the flashing material using a felt tip pen. There is plenty of material to make the boards any size you want.
Using the aircraft tin snips, cut the plastic flashing to the template shape. Trial fit each Air Board to the car and trim/file/sand as necessary to get a good fit. Also bend the front air boards to fit the contour of the lower inside portion of the front fender well. Hand bending works but a heat gun can make it easier. There should be a maximum of 1/16th inch gap between the boards and the fender well, any more and the gluing will not work.
Using Steel wool, rough up the surfaces to be glued, both on the boards and the fender well/side skirt. Also clean each surface with soap/water and then alcohol. Failing to do these steps will prevent the glue from adhering.
Now is the fun part, apply glue to both surfaces to be joined, let dry until tacky then mate them together. On the front boards wedge a piece of cardboard or an old shoe between the tire and the board to act as a clamping force. This is necessary to prevent the board from springing back causing a gap.
Let dry a minimum of 1 hour before removing the clamp.
Finally, clean of the excess glue and apply a smoothing bead of black silicone sealant at the edge surfaces of each board.
That's it.
The end results were about 75% of what we wanted to achieve, if we did it again we would make the boards a bit bigger, especially the rear boards. We would also look for an adhesive that was easier to use and had better contact cement qualities, (So no clamping would be required).
1/29/03 Copyright 2003, skoshiracing