heinzboehmer's 2002 Topaz 6MT Coupe

[heinzboehmer]

Rough ballpark on cost to reproduce your E86 brace setup?

Hmm, here are my guesstimates for just materials (not accounting for welding/machining/install labor, 3D printer cost, tools, etc.):

• E86 braces: $100
• Windshield mount CNC machining: $1000
• Laser cut parts: $150
• 3M adhesive: $100
• Filament for HVAC plastics: $200
• Fasteners: $100

So a total of roughly $1650 for parts. Let's say $2k all in with labor and random tools you might need to buy.

I'll add a detailed cost breakdown of what I paid for everything to the assembly/install document I'm drafting up. Should give people a good idea of what to expect.

[D-O]

Rough ballpark on cost to reproduce your E86 brace setup?

[heinzboehmer]

Nice to have more more voices on the benefits of front end triangulation, as I kind of felt like a shill when writing up my Slon front brace review. But, it just is transformative! It's not shilling if it's the real result!

Ohh yeah, the improvement is very real. Everyone who's driven the car has immediately felt a difference.

One of my friends who drove it on the street was at the track day and we swapped cars for a session. I made him do the AB test and he was amazed by how much better the car behaved in the corners.

He brought his 981S on PS4Ss, so I drove that when we swapped. I was able to keep up with my non-braced M3 in the Porsche, but the braced car outpaced me.

(I'm sure the 981 would absolutely destroy the M3 on proper tires, that thing is crazy fast)

I have a bunch of data from the day that I still need to analyze. Will be interesting to see what the data says about braces vs no braces.

[Obioban]

Nice to have more more voices on the benefits of front end triangulation, as I kind of felt like a shill when writing up my Slon front brace review. But, it just is transformative! It's not shilling if it's the real result!

[heinzboehmer]

Some updates from the recent track day:

• Firewall plug survived!
  • I still measured 80C at the firewall even after a full 30 min session. Seems like PET-CF is more than adequate.
  • Intake is LOUD in the cabin with this printed version. Not complaining about that at all!
• Frenkit/Ohio Performance Solutions dust boots also survived!
• Car absolutely hated being driven hard at 95F ambient with the AC blasting.
  • We were allowed to run windows up cause of the heat (which was really nice, actually), but I had to forego the AC as the day went on.
  • Once ambient temps got to the high 80s, the coolant temps would climb after a few laps. AC off + shifting at 7k largely resolved the problem (but instigated lots of complaints from the driver).
• E86 braces are awesome on track.
  • Grip increase is immediately obvious. Braces give you soo much more confidence. Ended up doing a bunch of AB testing because it was so entertaining to feel how different the car was to drive with and without them.
  • For reference, with the braces installed, I was able to take turn 8 at 105 mph (indicated) without any drama. I had to be pretty damn brave to get close to 100 with no braces.

I really need to sit down and finish up the cabin air filter housing CAD so that I can finally call the E86 braces project finished...

[Bry5on]

Why do you say?

Allegedly the carbon stays on the inside, so you don’t run the risk of handling fibers after you print.

[Obioban]

You can always get fancy with the siraya tech core line:

Why do you say?

[Bry5on]

You can always get fancy with the siraya tech core line:

[Obioban]

It's pretty amazing. I'm curious to try PPA-CF as well, but that's significantly more expensive.

I'm also still unsure whether or not I like handling these CF reinforced plastics. Prusa ran some tests on their filaments and came to the conclusion that they're fine, but not all the other filament manufacturers are doing this: https://www.reddit.com/r/3Dprinting/...prusament_lab/

I will absolutely wear a respirator and gloves if I ever need to sand any glass/CF reinforced parts, but maybe I should be more careful whenever I'm handling the materials.

After writing the post above, I've been researching filments till now... and ended up ordering Prusa's PETG CF. From what I gather, surface finish is a little better still, in exchange for heat tolerance-- so won't be using it around exhaust bits.

... going to save it for special occasions. Really went down this road because I want to print a bezel for the trailer brake controller I just ordered for the Land Cruiser.

[heinzboehmer]

ummm... ordering.

That seems amazing for parts in visible places. Tired of sanding/painting plastic :P

It's pretty amazing. I'm curious to try PPA-CF as well, but that's significantly more expensive.

I'm also still unsure whether or not I like handling these CF reinforced plastics. Prusa ran some tests on their filaments and came to the conclusion that they're fine, but not all the other filament manufacturers are doing this: https://www.reddit.com/r/3Dprinting/...prusament_lab/

I will absolutely wear a respirator and gloves if I ever need to sand any glass/CF reinforced parts, but maybe I should be more careful whenever I'm handling the materials.

[Obioban]

Printed the firewall plug (no insert) out of PET-CF. My mind is blown every time I see this material get printed, surface quality is just nuts

ummm... ordering.

That seems amazing for parts in visible places. Tired of sanding/painting plastic :P

[heinzboehmer]

Oh definitely! Once it's 100% finished, I'll need to sit down and condense all the erratic thoughts I've written down here into some concise format. Will likely create assembly and install instructions of sorts.

Will be useful to anyone trying to replicate, but also to myself. There's no way I'm remembering all the nuances associated with this project a year from now

[Mike RT4]

I appreciate that it would be a ball ache to reproduce.

Once fully finished, would you be able to list all the third party places you used to supply everything needed and all the final iterations of the STL files etc all in one place so that any one can replicate?

[heinzboehmer]

Any plans to offer it as a kit ?

I'll be sharing all the design files when I've finished with everything. I don't really have the time/willingness/etc. to assemble a kit myself and sell it, but anyone is welcome to use/modify my design.

And what changes required for RHD ?

I think none! The windshield mount is the only thing that would be different between LHD and RHD, but I landed on a design that's symmetric, so it should work for both. Let me know if you want the STL to print out a prototype for testing on your car.

[Mike RT4]

Any plans to offer it as a kit ? And what changes required for RHD ?