Problems with OEM Aero Kit for 2009+ 2nd Gen FXs (and solutions!)

[jbaker1121]

Many people have begun to get the OEM aero kit.
I've had it for a while, and noticed a few issues with it before the most current problem.

- The fitment is not the best, and it takes some effort to get it to fit perfectly.
- The mounting points are not terribly secure; there is still some movement when installed.
- The mounting points under the car are simply screws drilled into the plastic with not securing bracket or nuts on the other side.
- The flimsy plastic on the mounting points can easily be bent and broken.
- glue is needed to fit the top portion, with the only mounting points being on the bottom of the lip itself.

However, my most current problem was probably a worst-cae scenario and I'm happy it did not cause an accident or any harm.













I guess the factory aero kit wasn't actually made to withstand high speed driving for long periods of time...

I Drove to boston and back last week; on the way back, on the highway, while doing around 90, the front lip came off of the car, went under the car, and out the back. I drove back around to go pick it up.
I did not hit anything; I did not hit anything the day before nor did I ever hit anything in the front so there is no reason for me to believe that something was wrong with it. it just came off the car while I was driving.
Upon inspection after I got home: the mounting points on the lip itself all broke and the body glue on the two parts connecting the top portion did nothing to save it.

replacement cost is $700 installed. I've ordered a new one and it should be in next week. I will be working on making additions to the lip in order for it to be more supported and less likely to fall off again.

The mounting points under the car are simply screws drilled into the plastic with not securing bracket or nuts on the other side.
The flimsy plastic on the mounting points can easily be bent and broken.
glue is needed to fit the top portion, with the only mounting points being on the bottom of the lip itself.

These are all problems.
With an Aero kit, shouldn't it be made to actually withstand speed and promote the aerodynamic flow of air?
I know the pictures don't really do anything but show the damage, but this was a scary ordeal - the lip came off at speed, I ran it over, swerved a bit, and watched the lip flip around the road in my rear view, almost causing an accident.
When I went to retrieve the lip, it was in two pieces and cracked and scratched all over - I could not find the driver wheel well mount.

The new lip should be in next week. I will be making additions to the design and install of the lip to ensure a secure fitment and proper mounting to avoid any issues in the future.

These include the following: (the list will most likely grow)

- Reinforcing the mounting location
- Nuts on inside of mounting screw/bolt location to ensure it does not slip out.
- Addition of a lightweight sheet of plastic/metal to add to under-lip aerodynamics and promote air flow.
- additional mounting on top of lower bumper openings (currently only mounting lcoations are on bottom; glue on top)
- Possibility of molding lip to bumper at body shop
- Possibility of using rivets on lip.

This thread will be updated with these design additions for all of those who wish to do the same to do so.

 

[Fire0nic3FX]

That sucks the fitment on mine is perfect and its not loose at all. Mine has been perfect and ive had it on my ride longer than you.

Maybe the dealer installed yours incorrectly? Thats why I did it myself.

 

[RIPnFX]

Dang sorry that happened to you man, I have the whole kit and it fits like a glove and never had any issues as well but I've only had it a year so far.

 

[DaveButcher]

Wow man. That sucks! Good thing you didn't wreck or that it didn't hit anyone though. Interested to see what measures you're going to take to make it more secure next time.

 

[aiya]

Is it an option to inquire with the dealer about a possible improper install? I assume not since you've already gone ahead with getting a replacement on your own.

 

[jbaker1121]

That sucks the fitment on mine is perfect and its not loose at all. Mine has been perfect and ive had it on my ride longer than you.

Maybe the dealer installed yours incorrectly? Thats why I did it myself.

Dang sorry that happened to you man, I have the whole kit and it fits like a glove and never had any issues as well but I've only had it a year so far.

Wow man. That sucks! Good thing you didn't wreck or that it didn't hit anyone though. Interested to see what measures you're going to take to make it more secure next time.

Is it an option to inquire with the dealer about a possible improper install? I assume not since you've already gone ahead with getting a replacement on your own.

I spoke to them and they followed instructions and had their body guy do it. I dont think there's a way to do it incorrectly besides what I mentioned with no nuts on the bolts/screws on the bottom part. I dont think they way they designed the installation was made to take high speeds for a long period of time or something....
There's really nothing I can do. I'm friendly with the manager of the dealer and we also know the owner of the dealer.
I will just have it installed again and will take the extra step to add extra reinforcement. good thing I did not add my additional custom parts to it before this.

 

[Fire0nic3FX]

I drove from here to Ohio and back a total of 16 hours last year doing speeds of 70-95 and mine didnt come loose. Mine has also been taken off and removed 3 times for painting and its still solid.

 

[turbocad6]

I've installed a few of these. the last one installed had some additional clips that went in the center part that the first 2 did not have, not sure if they were missing from the first 2 or if they updated the mounting, but basically the center where the double sided tape goes, on the irst 2 the tape went to the bumper cover but on the last one, the tape went instead to these clips... looks to me like they did this to make it removable without having to undo the double sided tape...

either way, if you really want it to stay on there I would suggest doing what I do on a lot of body kits, which is to get yourself a tube of windshield urethane and put a few strategically spaced blobs at appropriately cleaned spots, once this urethane cures you will have a very hard time removing the lip but it will def not fall off, it can be removed if needed but takes a lot more work and cutting of the urethane so don't overdo it, a little goes a long way, but if you're using it in a space with a void then make sure your "blob" is tall enough to contact and compress to the opposing surface, yet not so much that it's going to ooze out and show anywhere..

now all that said, this lip is designed in such a way that as long as the 2 sides are firmly "pinned" in place, then the rest of it really can't fall down, it's kind of hooked all through the center and as long as the 2 sides are pinned it shouldn't go anywhere, even if it can move around a little bit if the double sided tape isn't secure. many bumpers on newer cars are just held on mainly by being pinned on both corners, the rest just fits the form of the reinforcement beneath it, or in your case the bumper beneath it...

if I had to guess I would guess that you may have caught the lip on one of those parking barriers and pulled it a bit, compromising one of the side mounts, otherwise this should not have happened even at well over 100mph

 

[IridiumFX]

Whoa! Now you got me all nervous. Looks like it might be worth poking my head underneath the car to ensure that ours is still firmly secured in place. Glad to hear that nobody got hurt through this. Sorry this happened to you!

 

[IonicDynamics]

now all that said, this lip is designed in such a way that as long as the 2 sides are firmly "pinned" in place, then the rest of it really can't fall down, it's kind of hooked all through the center and as long as the 2 sides are pinned it shouldn't go anywhere, even if it can move around a little bit if the double sided tape isn't secure. many bumpers on newer cars are just held on mainly by being pinned on both corners, the rest just fits the form of the reinforcement beneath it, or in your case the bumper beneath it...

if I had to guess I would guess that you may have caught the lip on one of those parking barriers and pulled it a bit, compromising one of the side mounts, otherwise this should not have happened even at well over 100mph

Totally agree with him, most likely the wheel well flanges were loose/mounting points were compromised. It's always a good idea to use a good quality urethane adhesive with front lips, I've used sikaflex to install many front lips and other parts were drilling would ruin the look.

jbaker1121: when you get the new lip installed inquire about them using a urethane adhesive along the contact points that the lip has with the bumper.

 

[jdTrader]

nothing to see here, move along.

 

[GEE50FX]

I have a new OEM lip in my basement that I will be installing when I get a chance. I don't plan on changing anything from the OEM instructions. The lip I had on my 09 FX had perfect fitment and I had no problems with it. It was on the car for quite a while, I think I was the first one here to install it on a FX with the full tech package.

 

[Fire0nic3FX]

This was definitely a freak accident kind of thing or an improper installation. No one on here should worry as long as you follow the instructions.

 

[jbaker1121]

I've never hit ANYTHING with my car, not even one of the parking bumpers. I generally throw on the front camera to pull in to make sure I hit nothing. I did have my car valet parked in Boston before I drove back, and a few times in the city to visit the GF - Maybe they bumped something and loosened it then the driving there and back killed it.

Update: They've ordered a new one and it should be in next week. I'll ask about the mounting putty and will probably reinforce it myself.

 

[IridiumFX]

I have a new OEM lip in my basement that I will be installing when I get a chance. I don't plan on changing anything from the OEM instructions. The lip I had on my 09 FX had perfect fitment and I had no problems with it. It was on the car for quite a while, I think I was the first one here to install it on a FX with the full tech package.

Hey does anything different have to be done to install the lip with the tech package. The OEM lip says something like "not compatible with tech package." Do any modifications have to be done or is it the same install as before? Just wondering... Thanks in advance.

 

[Fire0nic3FX]

Nope nothing to worry about withe the tech package. I have it on mine without issues with the tech package

 

[GEE50FX]

What Aaron said, and the install is the same. I have never had a problem with the sensors.

 

[roughx021]

So did anyone figure a way to reinforce the lip?

 

[jbaker1121]

So did anyone figure a way to reinforce the lip?

The ways to do it are the ways we listed, adding extra bolts with big washers for security, extra mount points underneath, etc.

 

[roughx021]

Where did you guys put the rivets? Any way to secure the top portion of the lip, where the retainers go, as a reinforcement to the double sided tape? Or is the bottom only needed to be reinforced?