E86 Front Triangulation Braces Retrofit

[discoelk]

Not knocking the current design. I just think there is probably a simpler single piece way to do it. It may require deviation from the Z4 rods though. Not really sure til I dig into it a little more.

[bigjae46]

I think a full machined or burn/bend strut bracket may be the way here. I was gonna springboard off the Heinz design and come up with something eventually. I'll post it up when I get to it.

Machining a whole new part would likely be the best option based on Heinz' design if for no other reason would be easier to execute. Send off a file, machine it, install it. Otherwise, I don't see a reason to do something different from Heinz's design. It reinforces the plate, adds a load tested mounting point, and paint it black to look OEM.

[discoelk]

I think a full machined or burn/bend strut bracket may be the way here. I was gonna springboard off the Heinz design and come up with something eventually. I'll post it up when I get to it.

[bigjae46]

Following… great work at a better barrier to entry. Perhaps someone with more CAD experience than me could measure/scan the OE strut tower mounts for the bar and add blended provisions for the firewall bars? Might be expensive in machining costs, but would look a ton more OE+.

This could save the need to hack up the OE strut tower brackets, and lower barrier to entry further for those who don’t have the resources to weld. Just a thought! Definitely foresee this becoming a must-do mod for a lot of people.

Absolutely. Or someone can make a mold of a modified plate. The question is how to produce a part even if it is 3D scanned. Heinz's process of modifying and adding to an OEM plate I'd guess is less costly than making a whole new part.

I think Heinz's part looks 95% OEM. I'd give it a 99% if everything was painted black.

Just to be clear, I deleted the cabin air filter housing a long time ago. So the tab I molded in for the extra bars probably won't line up with the modified cabin air filter housing parts.

[ParliamentLights]

Following… great work at a better barrier to entry. Perhaps someone with more CAD experience than me could measure/scan the OE strut tower mounts for the bar and add blended provisions for the firewall bars? Might be expensive in machining costs, but would look a ton more OE+.

This could save the need to hack up the OE strut tower brackets, and lower barrier to entry further for those who don’t have the resources to weld. Just a thought! Definitely foresee this becoming a must-do mod for a lot of people.

[bigjae46]

Mold is almost done. Have to do some minor repairs and clean up.

[bigjae46]

Pics when done please!

Absolutely!

[heinzboehmer]

Pics when done please!

[bigjae46]

Working on the strut tower plate compression mold. I added a tab for the firewall tubes. Just needs a little more prep, install the barrier fences, release, and then pour the casting resin. I will use long strand carbon for better strength and stiffness properties. I may add additional steel reinforcement underneath where the bars bolt to.

This should be cheaper to make but may require a different brace bar. And the tab may not be on the same plane as the firewall mount so the tubing may need a bend.

[heinzboehmer]

Looks so OEM an clean! Great work.

Epic! Not many DIY projects incorporate an actual performance improvement and maintains all OE functions, serviceability and aesthetics. Remarkable!

Thanks!

Did my best to retain all OE functions, but I'd be lying if I said there wasn't some compromise. Fortunately, the compromise is almost entirely related to the install of the modified HVAC plastic parts.

There's just more stuff crammed back there (braces and all the gaskets needed to seal around them), so it takes a bit more wiggling to get it to seat nicely. The access for the middle fastener on the cabin air filter housing is also tight, but it does work just fine.

Everything else is very much stock-like

[bigjae46]

It's done!



Well, sorta. Still need to do some finishing work (sanding, painting, etc.) to make it truly invisible in the engine bay, but all design work is complete.

I'll try to spend some time this week bringing the documentation up to speed. Will update here when that's finished.

Epic! Not many DIY projects incorporate an actual performance improvement and maintains all OE functions, serviceability and aesthetics. Remarkable!

[0-60motorsports]

It's done!



Well, sorta. Still need to do some finishing work (sanding, painting, etc.) to make it truly invisible in the engine bay, but all design work is complete.

I'll try to spend some time this week bringing the documentation up to speed. Will update here when that's finished.

Looks so OEM an clean! Great work.

[heinzboehmer]

It's done!



Well, sorta. Still need to do some finishing work (sanding, painting, etc.) to make it truly invisible in the engine bay, but all design work is complete.

I'll try to spend some time this week bringing the documentation up to speed. Will update here when that's finished.

[Maxhouse97]

This looks awesome, an alternative to the Slon brace that I so wanted (I love chassis rigidity) but could never justify spending that much money on. But it does seem a little intimidating for a guy who has never worked with a machine shop or welded (I do great at bolting on stuff🙂).

EDIT: In reference to my question above, I went back into the Google doc in detail.

Again I would like to recognize Heinzboehmer for his amazing ingenuity, dedication, and attention to detail of this design. It is truly high watering for an enthusiast to do this themselves. And the fact that this has been provided all open source, free of charge, is a testament to him, this website and the community in whole.

However, with the amount of 3-D printing, CNC machining, and other welding/fabrication currently involved i’m not confident in my ability to do this. I will cheer you all on from the sidelines and wait until either this develops into a full purchasable kit (if Heinzboehmer or someone else so chooses) or bite the bullet for the Slon brace. This makes the Slon brace look not as overpriced as I thought before. If it weren’t for that damn cabin air filter housing…

[heinzboehmer]

Fack! I store my car at the track, 40 min away and I forgot to measure how long.

Could you hook a brother up with the length too? Damn I'm a pain in the ass! 🤣🤣🤣

Lol all good.

My design puts the brace mounting studs 555 +- 10 mm apart.

I don't really know how long a stock E86 brace is, as the ones on my car have been shortened a but. Guessing stock is closer to 600 mm.