A friend of mine has an audi A4 and wants a decorative one from 1 piece of ABS (or 2... specifically no wood) to mimic a rocket bunny, so come october I'll be taking measurements and stuff. I think if I do this again I'll remove the wood from the equation - having never worked with thick ABS before I didn't realise just how strong and resistant it is. The aerofoil could've just been a curved groove to bend a panel in to shape and mounting points on the side could all have been 1/4 - I'd just reinforce some points with extra wide washers. The cost would likely come out to that same.
Being a first run though, and retaining wood templates if I wanted to build it again, time wise I'm sitting at ~3H cutting ~4H sanding and planing 2 nights wasted to painting - (reason alone to replace the wood with ABS, and I still have to give the wood a final coat of penetrol and a a thick coat of plastidip just to seal all the tiny gaps), ~5H bending / assembly... and like 7H of shopping for parts lol side note - only the really beefy metal brackets from homedepot will accept 1/4-20 bolts... found that out the hard way and drilling out holes can take a while with so many of them.
To do it again but solid ABS... it'd likely drop from the ~19 hour first run, to about 6 if I preemptively had all the mounting hardware and bolts figured out
View my fuel log 2015 Micra SV automatic: 7.1 L/100 km ... 39.9 mpg (Imp) ... 14.1 km/L ... 33.3 mpg (US) ...