A few questions regarding the Kevlar carrier: Repair, Wire Harness, Styrofoam.

[///M3RIC]

Hello,

In the process of removing the auxiliary fan I decided to completely remove the carrier for easier access and general cleanup. When I unbolted and dismounted the carrier, fragments of Kevlar flaked off. Especially concerning are the bits that left the bolt holes wider than they were before. Has anyone ever patched the carrier? I’m looking into fillers, fiberglass, patches, tapes, epoxies, bigger washers, etc. Anyone have experience with this?





Also, while disassembling I moved aside the harness that I have nothing attached to, I think the previous owner removed the parts these attach to... There are nine plugs total, I don’t plan on replacing all the missing parts, except for the horn and temp sensor, I’m just not sure what they are all for or if the harness can be removed entirely except for the connections I need. Can anyone identify which connections are for what parts? I think 1 and 2 are for the low and high horns and the rest I’m not sure about but I’m thinking temp sensor, fog lights, windshield reservoir…?





Last question, has anyone replaced the Styrofoam that sits on top of the carrier to support the bumper? I don’t think those pieces are sold anywhere except eBay. Anyone done a DIY cutting Styrofoam, or got lucky and found strips that match the size? Just the height would need to be precise, the length and width could vary some. Any material options besides Styrofoam?


Thank you for any input!

[///M3RIC]

After further research I’m thinking the nine plugs are: 2x horn, 2x fog light, 2x headlight washer, 1 temp sensor, 1 washer fluid pump, 1 washer fluid level sensor. I only plan on keeping the horn and temp sensor, figuring out which those are once I get the parts should be easy enough.

I’ll end up trying one of the Kevlar repair methods mentioned above, I’ll update with how it goes.

For the foam I’m going to try my hand at cutting up some styrofoam strips.

[WestBankM4]

Refer to this thread for help regarding the styrofoam. I am using this as a guide when I eventually get my Euro bumper painted and installed.

[Maxima SE]

For the foam on the kevlar carrier. I used a 1/2" pex pipe for the longer outer piece and it has worked fine. For the shorter inner piece, I plan to use a 3/8" pex pipe and see how it goes. You can use double sided tape and if you're happy with it then you can epoxy it. I wish someone would measure the height of these things so we can get a better idea how high they are.

https://www.homedepot.com/p/SharkBite-1-2-in-x-2-ft-Straight-White-Pex-Pipe-U860W2/205047980

https://www.homedepot.com/p/Apollo-3-8-in-x-5-ft-White-PEX-B-Pipe-APPW538/301541220

Now I know yall are gonna say this is ghetto but the whole front bumper design is ghetto to begin with. the foam pieces suck and the foam behind the back of the bumper tears easily too. I wish they did a better design.

[///M3RIC]

For the foam on the kevlar carrier. I used a 1/2" pex pipe for the longer outer piece and it has worked fine. For the shorter inner piece, I plan to use a 3/8" pex pipe and see how it goes. You can use double sided tape and if you're happy with it then you can epoxy it. I wish someone would measure the height of these things so we can get a better idea how high they are...

I think this is a good idea, if it works, why not?

As for the measurements, I found this on m3cutters:

width - depth - height

2x Outer: 10 - 3/4 - 1

1x Middle: 17 - 1 - 1/2

2x In between outer and middle: 3 1/4 - 1 - 5/8

I haven’t verified if these are correct

[Maxima SE]

I think this is a good idea, if it works, why not?

As for the measurements, I found this on m3cutters:

width - depth - height

2x Outer: 10 - 3/4 - 1

1x Middle: 17 - 1 - 1/2

2x In between outer and middle: 3 1/4 - 1 - 5/8

I haven’t verified if these are correct

so the outters are 1" high and the small piece in between is 5/8 high?

[///M3RIC]

so the outters are 1" high and the small piece in between is 5/8 high?

I suppose so.. here’s an image with measurements I found by googling e46 m3 bumper foam measurements. Once again, I haven’t verified these myself.

[Maxima SE]

I still have the middle piece so I will verify measurements tomorrow since my bumper is off. I really did not think the outters were 1" thick but 1" and 1/2 PVC tubing should be cheap and easy to find at HD or lowes. Does not have to be an exact science
"

[bigjae46]

There should be an aluminum plate that attaches to the kevlar part which secures the bar to the front rails. Looks like its missing.

If the car was towed by the tow hook then it is common for the aluminum plate to separate from the kevlar. You can try epoxy but once the kevlar fibers are compromised and break, they lose all of their strength. Then you'll need to add some kevlar and epoxy.

[Maxima SE]

I suppose so.. here’s an image with measurements I found by googling e46 m3 bumper foam measurements. Once again, I haven’t verified these myself.

I compared to the long piece in the middle and the measurements are super close but not exact. I looked at the gap between the headlights and kevlar bracket. I think 1" on the outter piece and 1/2 for the piece next to it would be great. I will probably do that this weekend since my bumper is off the car.