heinzboehmer's 2002 Topaz 6MT Coupe

[heinzboehmer]

Really happy with the design of the firewall plug insert. Prototype fits great and the magnets make it snap right into place, can almost just throw it on and it'll go where it needs to:






(tape is only there to hold the magnets in place, didn't want to glue them to the prototype)

Quick video showing how careless you can be when installing, it's pretty great:

[heinzboehmer]

You could do a sort of tongue in groove too. I’d be trying to make the gasket a simple cross section if I were you.

Yep! Tongue in groove is how the larger gasket is designed. That's just gonna be a loose press fit like the stock firewall gasket is.

The smaller ones that seal against the braces have a T slot so they slide into place.

I made sure all gaskets were just a simple profle (a U and a T) swept around the sealing area. They will likely be a bit challenging to print due to all the bends, but should be pretty simple to cast.

We'll see how it goes.

[Bry5on]

I think some sort of adhesive gasket is the last resort. I really want make this style gasket work, it just feels more elegant (and serviceable).

You could do a sort of tongue in groove too. I’d be trying to make the gasket a simple cross section if I were you.

[heinzboehmer]

You could make the seal out of neoprene sheet, it’s pretty easy to cut to shape, especially with a fixture, and it’s available with adhesive backing. Just an idea

I think some sort of adhesive gasket is the last resort. I really want make this style gasket work, it just feels more elegant (and serviceable).

[Bry5on]

You could make the seal out of neoprene sheet, it’s pretty easy to cut to shape, especially with a fixture, and it’s available with adhesive backing. Just an idea

[0-60motorsports]

Amazing work heinzboehmer

[heinzboehmer]

Finally sat down to finish the design for the firewall plug. As mentioned, the removable insert that provides tool clearance was the only part that still needed work. This is where the design is at:




Those two tabs house the magnets that hold it in place before the filter housing is fastened. I'm fairly confident they'll be strong enough to hold the part up, but I might have to tweak that part of the design a bit.

Currently printing out the insert to prototype with. I did a lot of guessing with the clearances needed so that it can pivot forward and out, so it will definitely need some testing.


As for the gaskets, I'm thinking of printing them out of this stuff: https://recreus.com/en-en/products/filaflex-82a

It's a bit firmer than I would like, but I really need something that can withstand the heat in the engine bay. Vicat softening temp for that stuff is 113 C, so it should be fine. If that doesn't work, I'll have to resort to printing out molds and casting some silicone gaskets.

[heinzboehmer]

Also, I feel like I should clarify this. I am in no way trying to compete with Slon or offer a cheaper version of their kit. Slon pioneered and tested this idea and should receive all the credit for it. I never would have started this project had I not driven a car with the Slon brace installed.

Mine and Slon's versions are simply optimizing for different things and both have their pros and cons. Mine is optimizing for max "factory-ness" (including the crash safety stuff) and for ease of removal to make engine work simple. Slon's is optimizing for stiffness of the part and minimal interference with the cabin air filter housing.

I would really only pick my version if you care about what I mentioned above our if you want a much more involved project

[heinzboehmer]

The windshield mount using forged carbon fiber would be about 1/2 the cost of the CNC part.

Yep! That's also an option.

[bigjae46]

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.

The windshield mount using forged carbon fiber would be about 1/2 the cost of the CNC part.

[heinzboehmer]

2K is still much less than the Slon kit, and I must say it looks "factory" from your photos. Impressive. Most impressive.

D-O

Thank you! That really means a lot.

I've put a ton of thought and effort into making sure it doesn't look out of place, glad to hear it has paid off. Should be very hard to tell it's not stock, once I've smoothed out the strut tower brackets and painted everything black.

[D-O]

2K is still much less than the Slon kit, and I must say it looks "factory" from your photos. Impressive. Most impressive.

D-O

[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.