How do I build a Lexan spoiler?

I want to add a Lexan spoiler to my 4th-gen Camaro ESP autocross car. Anyone have any tips on how to build and mount a simple blade-type spoiler?

mock up with cardboard. make smooth cuts. sand down the edge for uniformity. make sure you have turnbuckles that will support the air, as well as provide adjustability.

What's the best way to actually fasten it to the decklid?

either fabricate angled brackets, or you might be able to use a solid mount hinge...

Apparently, all you need to do is ask me to make a window out of it and you will get a pile of spoiled lexan approximately equivalent to the amount of unspoiled lexan sheet you originally had.

Why get all fancy.

I made a lexan rear spoiler for a oval track car out of a piece of lexan, two screen door hinges and a couple pieces of aluminum bracket of a conveyor belt.

Pretty sure it cost me less than $10 to make. One trip to Home Depot for the hinges, and the lexan and brackets were free.

I also drilled a couple extra holes in the body so I could adjust the angle. everything was held together with 1/4-20 bolts

Make sure you use LEXAN...

I once cheaped out and got some off brand crap, it broke in a day.

if not lexan, alternatives include sheet metal (steel or aluminum) fiberglass(if you want to put more time and money into it, and choroplast if your not looking for a long lasting solution/good looking solution

Lexan can be bent in a brake. You could just bend a flange and use big rivets to fasten it to the trunk. Then use supports to make it strong.

The turnbuckle and hinge idea is pretty good thinking. You may decide to change the angle later on.

Depending on the data you get back after the wind tunnel tests..

Any real polycarbonate will be fine. Lexan is just GEs name for it. Do NOT get petroleum stuff on it, it will get brittle in no time. A wood planer, the manual kind, works great for cleaning and straightening up wavy saw cuts. Polypropylene should also be sufficient at much lower cost. McMaster.com part# 8742K632 $16.33 and should be enough to screw one up. PETG should also be a cheap alternative (similar to plastic bottle material).

i had this thought the other day - thinking of adjustable spoilers with turnbuckles while thinking i wanted to find something huge from the 60's and do a vintage stock car look alike.

piano hinge - it will give support across the whole front edge and they come in all kinds of finishes. it would work well on all but really curved surfaces.