QUOTE (DaveW @ Nov 9 2009, 08:37)

Not my subject, but be wary of More's Theorem (with apologies to FB). Think expansion ratio (as the D/F builds, the chassis is pulled down & the venturi expansion ratio increases). At some point (airspeed) the flow will separate & D/F will reduce significantly. The result is normally called porpoising.
Completely true. I was overstating things a little. Never take me too serious....
There aren't too many modern racecars with tunnels to look at. The Lola and Reynard ChampCars were very limited by the rules on what they could do, but the tunnels were still very strong. The Panoz was much less limited and the tunnels for it were significantly larger, even though they stopped at the rear axle centerline. Things like the late 80's-early 90's GTP cars are amazing to me. The shear volume of those tunnels is intimidating.
For a small car, I think you'll run out of real estate before you stick too much tunnel on it. 4* is certainly not even close to getting you into trouble. You'd probably have to be 3, maybe 4, times that before even considering a 'too big' problem. To stick some number on it, at 12*, if your diffuser is 1.5 meters long, then you're at a 31cm tunnel exit height, which at first glance isn't excessive. It's only slightly above axle centerline. In fact, you might need to go higher or lower so you don't have to deal with the tunnel and the axle crashing into one another. Just another packaging issue to deal with. If you think there's a separation problem, stick a 10mm gurney on the exit. Tunnel gurneys can be very powerful.