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(VinceBar) Front gusset cups for Convertibles

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    (VinceBar) Front gusset cups for Convertibles

    EDIT: Added pictures as I noticed that the YouTube video previews don’t show in the web version of the forum (as they do in Tapatalk).

    It’s been a long time coming, but now I’m finally in the development phase of the convertible specific front gusset cups.




    And in developing the vert specific front gusset cups I’ve decided to share the actual development process in real time.
    I’m thinking it may be interesting to follow the progress and see what conclusions and set backs I encounter.

    I’ll be sharing this on YouTube and posting the videos here in the NAM3 community.

    If you feel that these videos are helpful and educational please help me spread the knowledge and information by liking the videos.
    I’ve been told that the number of likes a video receives highly influence the YouTube algorithms probability to suggest said video to others that share our interest in the E46 platform.

    That said, let’s dive into this!

    As an introduction for those who might not be familiar with the front gusset cups, they are part of the PPRnD solution for addressing the so called Subframe (actually RACP, or Rear Axle Carrier Panel) failures.

    More specifically the front gusset cups address the, still fairly often overlooked, cracking of the topside of the front subframe mounts.

    I explain how and why these cracks occur, and how the front gusset cups address this issue in the following videos:





    Part 1



    Part 2



    There is also some valuable information starting approximately 10 minutes into part 4 of the “VinceBar and gusset cups overview”:







    If you’d like to watch all 4 of the “VinceBar and gusset cups overview” videos you can find the playlist here:




    list=PLg2TArrteKd4ttsu_Nr1SznnEw9N81cN7&si=fTeWQGH 4XIpbS0FD


    And now to the actual vert specific gusset cup content!

    In this first video I provide an introductory overview of the project as well as provide some tips on how to remove the interior in order to expose the area where we will be working:






    In this second video I provide some more detailed information on the challenges with this project:






    And in this third video, which I published as late as yesterday, I start diving into the actual development:






    So once you have watched these three videos you will have caught up to where I am in the development so far.

    In parallel I’ve also published some videos on how to properly inspect the underside of the RACP for damage. In these videos I also share tips on how to remove things like the brake lines and gas tank and its supporting tubes. And also tips on how to clean the underside of your car.

    This information is found in these two videos:












    Sent from my iPhone using Tapatalk
    Last edited by VinceSE2; 10-27-2023, 12:07 AM.

    #2
    Great news!! Indeed I've waited a long time for this. Thanks for all of your work, Vince!

    Comment


      #3
      Originally posted by ATB88 View Post
      Great news!! Indeed I've waited a long time for this. Thanks for all of your work, Vince!
      Thank you sir! 🙏

      I'm thinking that if there's enough interest in the vert specific kit I might run a group buy in December to celebrate the release of this kit.

      What do you vert guys think about that?




      Sent from my iPhone using Tapatalk
      Last edited by VinceSE2; 10-27-2023, 12:14 AM.

      Comment


        #4
        Awesome work Vince! Thank you.

        Comment


          #5
          I just posted the second design video for the convertible specific gusset cups on YouTube.
          Please find the link at the bottom of this post.

          In this video I continue the work on testing out the design of the convertible specific gusset cups. I find that I need to use a longer hole saw guide rod design and design a bottom side drilling and hole sawing guide sleeve to complement the longer guide rod.
          I also explain why this is the case and why it's different from the standard gusset cups.

          Here are some screenshots from the video:

          The steel tube test fitted in the gusset cup cavity


          I'm explaining how and why the “ridge” needs to be flattened


          Measuring the offset of the hole sawed opening.



          Showing where the hole saw should have been positioned


          The 100 mm longer hole saw guiding rod that will be complemented with a bottom side guiding sleeve


          This picture shows how the hole saw need the slanted cut in order to be able to enter at the correct position


          A top side view of the offset hole. This clearly illustrates the need for additional drill and hole saw guidance compared to the standard (non convertible) gusset cups.



          And finally, here's the video.




          Sent from my iPhone using Tapatalk

          Comment


            #6
            Here are a couple of pictures from a customer installation of the standard front gusset cups.

            Corey (whose forum username I actually don't know) is also here on NAM3forum.

            I wanted to share these to show the typical cracks that form in and around the MIG welds. In sharp corners of the weld and in the welds HAZ ( Heat Affected Zone).

            The 330i convertible I'm working on is luckily in great shape with only a hairline crack and a popped spot weld at the left rear mount.
            No damage at all to the front mounts. Neither bottom nor top side.

            While that is great for me as the cars owner, it's less ideal from a demonstration point of view.

            This is why I'm sharing these two pictures.

            This is the top side of the right front subframe mount. If you look closely you can see cracks that originate from, or around, the MIG welds.

            These cracks are very common on M3's and spirited driven (which my convertible doesn't seem to be) 330i's.

            This M3 already has the (I believe) TMS style subframe plates welded in since before the VinceBar/Front gusset cup installation.

            Corey, please correct me if I'm wrong.




            Here's the standard front gusset cup installed. In the picture there is still too much stick out of extended stud.



            It's a very clean and well done installation 👍😊


            Sent from my iPhone using Tapatalk

            Comment


              #7
              The fun has begun! 😁

              The CAD design has started and here’s a short reel:


              Last edited by VinceSE2; 11-06-2023, 11:39 AM.

              Comment


                #8
                Now the Front Gusset Cups for Convertibles project is getting fun! 😁👍

                Please check out the video at the bottom of this post for more details.

                I've gotten pretty far into the CAD part of the design phase. And so far evolved the first prototype, via seven iterations, into a design that im quite happy with. 😊👌

                I also found that the left and right sides are not mirror images. For some very strange reason BMW chose a different path 🤔

                Here are some pictures with accompanying descriptions/comments:

                Checking out clearance and accessibility so that the nuts can be tightened through the relatively small access hole.
                It worked out perfectly! 😁




                To the right the steel tube has gotten its correct size and shape.
                To the left is the first iteration of the face plate.
                The right side face plate that is… More on that further down.




                I've used the paper print out from CAD wrapped around the tube, traced the top perimeter, and then cut the tube on the traced line.



                The first iteration of the right face plate.



                The face plate placed in its planned location.



                A few of the seven iterations so far 😁



                The left and right face plates. Right is to the left in the picture. And left is consequently on the right in the picture 😉

                If you look closely you can see that they are not perfect mirror images of one another 😯



                The left side face plate in its location.

                The position of the hole slightly down to the right of my finger is different on this side. Probably a result of the shape of the opening above the face plate being different than the right side. This is extra work and requires two variants of the face plates… Why BMW? 😠




                Here's the full part 3 video:




                Sent from my iPhone using Tapatalk

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