Front Bolt-On Style Splitter For Post Facelift Volvo 700 & 900 Series

3D printable front lower "bolt-on" style splitters for post 1990 facelift Volvo 740, 760 and 940 sedans and wagons. Was part of a full bolt-on style body kit I was making for fun but I've since chosen a different direction with my own build. Releasing this part as a gift for the RWD Volvo community for all the helps I've got over the years.

Design features:
-Designed with motorsports in mind (drifting and autocross), true hollow body structure, economical two-piece design reducing repair costs and can be installed by one person without a buddy's help!
-Bolts directly to the lower bumper valance under the front bumper, drilling is required.
-Customizable height offset (flush with lower bumper or flush with lower bumper grille's bottom edge). Optional parts included.
-Customizable rear back bracing for different levels of structural strength (less bracing for sacrificial use or more bracing for permanent mounting and molding). Multiple height offsets to choose from depending on your needs!
-Designed with maximum amount of tolerance due to the nature of 3D printing as well as different dimensions of aftermarket lower bumper trim pieces and the ages of these cars. Post printing trimming and modification is expected, optional filler pieces included with the design.
-Additional hardware required, tooled for using 16 pieces M4 by 22mm screws, washers and locking nuts for mounting as the "economical" option, mounting holes can be bored up to use up to M6 by 22mm bolts. Shorter bolts can be used though 22mm is about the best length to make mounting a bit easier.
-Additional rubber edge seal or caulk sealant can be used.
-Splitter can be further reinforced by filling its hollow body with NON-BOWING expending foam. DO NOT USE regular gap filling spray foam!
-Offset mounting hole design can be filled in, allowing both splitter pieces to be molded together with the lower valance for a seamless, bolt-less look.
-Customizable rear back bracing requires either self tapping screws or additional nuts and bolts.
-Requires about 50-100 hours of time and labor for printing, trimming, finishing and installation.

Printing Guide:
100% infill with low layer height is recommended on all FDM prints, it's already a light weight hollow shell and it needs to be densely layered.

For drifting and other motorsports applications (where cosmetics don't matter much):
Use TPU for maximum flexibility, impact resistance and durability, if operating in hot weather where heat may cause the print to sag, reinforce internally with fiberglass resin coating or non-bowing expanding foam.

For daily use:
Use ABS, PETG(+), or nylon infused carbon fiber, PLA filaments are not recommended for exterior automotive applications, can be reinforced internally with fiberglass resin coating or non-bowing expanding foam if necessary.

For show car builds (smooth finishing or molding both pieces together for a seamless look):
SLA ABS-like resin and high quality ABS FDM filaments are highly recommended. Good quality ABS filament prints can be fused together with ABS pipe cement for seamless connections, and smoothed out with acetone vapor. ABS-like resin prints works well with Bondo and other body filler, as well as fiberglass & resin for custom looks and finishes.

Have fun building your bricks!

Have a wonderful new year! Remember to always be grateful, and know when to let go.

Standard Disclosure (Thingiverse):
This splitter is an original design.
This splitter is intended to be a cosmetic item, for non-road and off-road use only. Additionally, due to the natures of 3D printing, different installation and finishing techniques, I am not responsible for any damages caused by improper installation, finishes, or printing defects.
Installing this splitter requires irreversible modifications to existing lower bumper valance, make sure you are committed to install it before printing.
This splitter is not designed for any forms of manufacturing other than 3D printing by hobbyists. These files are created using Fusion 360 under a student license for non-commercial use only, and I am not responsible for any unauthorized third-party reproduction for commercial purposes.