Version 1 - 9.7 kg (ABS Plastic) is here http://mx5cartalk.com/forum/viewtopic.php?p=730055#p730055
Version 2 - 7.2 kg was made from ply 10mm with 2 layers of fibreglass on the bottom and 1 on the top. It has lasted quite well to be honest. http://mx5cartalk.com/forum/viewtopic.php?p=764135#p764135
Version 3 - 5 kg is made from 17mm Monopan http://www.lavender-ce.com/advanced-composite-materials/sandwich-panel-monopan/. This stuff is strong and light! However the edge does not take drilling too well. I'm getting some 1.6mm x 17mm U channel aluminium to put around the leading edge to protect it. Enough Monopan to make 2 splitters cost about $250. It is easy to cut but a bit painful to shape and trim. In the end I got an air angle grinder out and this worked well. Note this is also a bit bigger than the other 2 but weights LESS.
Version 3...
Monopan under the front after V2 splitter removed
DSCN2609 by Eipeip, on FlickrVersion 2 - after about 18 months of use.
DSCN2607 by Eipeip, on FlickrStarting to mark out (the red dot in the middle is in the flash shadow)
DSCN2613 by Eipeip, on Flickr
DSCN2612 by Eipeip, on Flickr
DSCN2615 by Eipeip, on FlickrCutting Plan. Made some changes to this version, an arch for the wheel turn radius.
DSCN2606 by Eipeip, on Flickr
DSCN2608 by Eipeip, on FlickrCut out (used an air panel saw, like a knife through butter)
DSCN2616 by Eipeip, on Flickr
DSCN2617 by Eipeip, on Flickr
DSCN2610 by Eipeip, on Flickr
DSCN2611 by Eipeip, on Flickr
DSCN2619 by Eipeip, on FlickrClose up of edge after a bit of a clean up. Started with a die grinder, not very effective. Then a 3" grinder that worked a treat. I used more clark rubber foam to fill up the air gap. A more permanent solution is needed, a work in progress. The gap is caused by the GV Lip not being perfectly flat/level.
DSCN2626 by Eipeip, on FlickrA great tool to clean up the edges after the grinder.
DSCN2625 by Eipeip, on FlickrThis is what the edge looks like close up with a bit of flat black paint.
DSCN2624 by Eipeip, on FlickrThis is where it stayed for a few weeks, until I could do the edge protection. I attached some rubber seal from Clark Rubber to protect it a bit. Monopan does not hold very well to screws put into the honeycomb middle structure. Fastners need to go perpendicular to the surface not horizontal.
DSCN2665 by Eipeip, on FlickrHow to bend the aluminium U channel that I planned on using. After loots of attempts I got a sheet of 18mm marine ply and cut out 1/2 of the splitter. I also attached a few hold down points to help it keep its shape.
DSCN2667 by Eipeip, on FlickrAfter heating the aluminium and 'tapping, it against the mould, a test piece.
DSCN2669 by Eipeip, on Flickr
DSCN2666 by Eipeip, on FlickrFinal version. It is held on with Sikaflex and riveted from the underside. I would have preferred to use peel rivets however they are not available over the counter in my area.
DSCN2675 by Eipeip, on FlickrA closeup of the edge inside the wheel well. A nice neat fit.
DSCN2676 by Eipeip, on FlickrFinished
DSCN2680 by Eipeip, on Flickr
DSCN2679 by Eipeip, on FlickrA few creases, I'll get better at shaping the aluminium, or sand it flat next time.
DSCN2681 by Eipeip, on Flickr
