A few of you know that I have been working on a "confidential project" but it light of the recent posts over in the General chat area I though I would bring it out in the open so as not to duplicate the efforts of others.
This morning I/we have just completed the tooling specs for an exact replacement of now out of production GT trunk seal. I have been working with one of the largest rubber gasket and molding extruders in the US and have done design work for them for years. The tooling itself is very complex and expensive and minimum quantities of the extruded gasket material are quite sizable. There are several issues that need to be addressed in order to move this project forward:
1) The gasket itself is composed of two different compounds of rubber, cellular and solid and is co-extruded along with a rigid metal clip that is embedded to grip the actual steel framework of the trunk surround. This poses a very big hurdle and several "tool dies" must be mated and the extrusion done in one piece.
2) The crush zone of the seal itself was designed to create a crease or grooved seal along the ridge of the underside of the trunk as well as the flat area of the trunk surface. If you look at the top "seam" on the trunk seal, you will notice the centerline was created intentionally to cause a uniform crease in the gasket. The has been duplicated.
3) The most common failure point in the seal is the underside of the crush zone and probably should be reinforced with a heavier gusset internally to prevent future failures. The problem with doing this reinforcement is that it changes the pliability of the gasket material itself. Our initial test have been very promising but until the gasket is tested in a real world application, we won't know if it will actually hold up better than the originals but lets face it, the NOS parts lasted 15+ years how much longer would someone expect?
4) The original was created using an embedded reinforcing thread material in the grip ribs that hold the gasket onto the steel frame. There was only one company in the US that produced such an extrusion and they have gone out business taking their patented system with them. Given the advancements of rubber and other synthetics as well as adhesives we do not feel the threading is actually needed in the replacement part.
5) Given that the only NOS parts that are still on the market are now well over 10 years old, even if in a sealed bag, the rubber will have lost some if not much of it's pliability. All carbon and petroleum based products have a shelf life and will eventually loose their flexibility. Also given that NOS examples are selling for $200+ we feel there could be an opportunity to produce an exact replacement for considerably less. Keep in mind that GM made in excess of 350,000 of these so their amortized cost is considerably lower that what we will be able to produce them for but we should be less than half of the current sell price of $200.
Now for the reality check, this project will take several more months to complete. The remaining who, what, when, where, why and how questions:
When: I am hoping to have a shipping product by the first of the year in time for the first spring shows but if our test extrusions are satisfactory we may be able to ship several weeks earlier. At this point I can't give a ship date until the tooling has been tested and samples have been field tested. I am not about to run several thousand feet of this material until I know for sure it meets or exceeds the factory product specs.
How (much): I am not in a position to give a final selling price at this point and given that we haven't finalized the co-extrusion standard, we don't know the exact cost of production. Using our initial estimates, we are shooting for well under the $100 price point. Back to the reality check now: If you are thinking you will be picking up a factory spec trunk seal for $30 a) you have a completely unrealistic idea of what it costs to produce these, b) you have no idea the R&D to make the tooling and co-extrusion work like the factory and c) you are probably not a candidate for this product. If, on the other hand you are interested in the highest quality part available and understand that the correct seal can save you a ton of money in trunk rust repair and aggravation alone, then your patience will be rewarded with a great solution to your problem.
I am not going to take orders on this product until it has been tested and further I am not taking deposits until we have a set price and firm ship date. I am not asking you to finance my venture. I am however, putting together a list of those interested in replacing their ragged GT trunk seal and for those who have custom trunks, we will be able to accommodate you as well. First on the list will be the first shipped. I also need to gauge interest to see if this is even worth perusing (I think it is, but my investment is sizable). Sooner or later nearly every GT Fiero will need a trunk seal replaced. I would rather make an exceptional product that will last rather than one that is "good enough". Quality is it's own reward. If you want to be put on the list, drop me a PM.
Best regards,
Will
••••• NOW AVAILABLE •••••
My GT Replacement Seals are now shipping and are priced at $95 + $15 shipping to the US (PM me for international shipping rates). Buy two and only pay the single shipping price! PM me your email address and I will send a PayPal invoice immediately.
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Thanks for the assist on the update Danyel
[This message has been edited by infinitewill (edited 04-19-2010).]
It happened by chance as I was doing some work for the company and I said to myself "self, if these people can't make it, nobody can". I was looking for a way to use my connections to build stuff that is out of production. I have several other ideas on the table but I want to get this in production and we will look at other products once this project in rolling. I will put both of you on the list if you would like.
There are almost 18k members on this site alone. Now I realize that there are alot of notchies out there, but alot of us on here have at least two Fieros. I myself have four, and two of those are fastbacks. So I think you have our attention and support. You can mark me down for at least two, and good luck to your R & D. We all will come out ahead with your efforts.
There are almost 18k members on this site alone. Now I realize that there are alot of notchies out there, but alot of us on here have at least two Fieros. I myself have four, and two of those are fastbacks. So I think you have our attention and support. You can mark me down for at least two, and good luck to your R & D. We all will come out ahead with your efforts.
quote
Originally posted by CowsPatoot:
Me too...I'm in for one down the road. About the time you get these ready, I will be ready to buy.
------------------ Rod Schneider, Woodstock, Ga. "You can't have too many toys!" 1988 Fiero GT 1985 Porsche 944 1966 Porsche 911 Van's RV-6 airplane-under construction
