E86 Front Triangulation Braces Retrofit

[ParliamentLights]

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.

I hope the sentiment of my post didn’t come off as a knock on the work done either haha.

I do like the idea of a carbon version akin to the OE M-performance or the strut bar although this would be counterproductive cost wise. Going to talk to a couple friends in aerospace mfg to see if they can CAD this idea further and give insight onto manufacturing prices. Something similar to the Dinan E90 m3 triangulation bars would be awesome.

[bigjae46]

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.

I didn't take it as a knock on the design. I'd like to see someone analyze a carbon part and engineer the layup to improve the strength. Especially how to secure the bars to the part.

I am using some knurled threaded inserts. The carbon/epoxy is compressed against the inserts so I think it should hold up to being torqued, twisted, and stressed. Would be nice to have some idea on whether this will actually work before live testing it.

threaded inserts | McMaster-Carr

[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.