Exploring Underbody Flow Management for the 991.2 GT3 RS Aero Kit: 3D Printing & CFD Analysis

Hey everyone!

I’ve started working on the aero kit for the 991.2 GT3 RS, focusing specifically on managing the underbody airflow with some custom strikes. To ensure the fitment and functionality, I used a scan of the 991.2 GT3 RS as a base to model and 3D print some test pieces. These pieces will help us test the fitment before moving forward with more advanced design refinements.

Next step is to perform CFD (Computational Fluid Dynamics) analysis to further fine-tune the design and make sure we’re getting optimal performance. I’m excited to see how this project progresses and will be sharing updates as I go.

Anyone here worked on similar aero mods? Would love to hear your thoughts or experiences!

 

3D printing is complete! Now it’s time to test the fit and confirm my design. I printed this on my Prusa MK4 using Prusment PLA. Since the part was too large for the bed, I split the model into three pieces. I prefer this approach because if something goes wrong, I only need to reprint one section instead of the whole part. For assembly, I used super glue—sets in 10 minutes and I gave it 24 hours to fully cure. The bond feels solid so far!

Next step: If needed, I’ll update the model, re-test the fit, then print the final design. After that, it’s installation and off to road testing!

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I've successfully designed and 3D-printed a direct plug-and-play solution for both the inboard strake and wheel well strake. These parts require no modifications, reuse the existing hardware, and integrate seamlessly with the OEM strake.

I'm currently looking for a few testers interested in trying out prototype parts at a reduced cost, with the expectation that you’ll provide feedback on fitment, functionality, and share images after track use.

If you're interested in participating or have questions, feel free to reach out!