Black & Tan 332iT

[Albino09]

Is this effectively an air scoop grabbing from the bottom of the wheel well? I can kind of make out the rough shape of the tire and the control arm but having trouble figuring out my xyz reference.

[0-60motorsports]

This will fit all M3s, and will provide effective brake cooling for a car with a CSL bumper especially. It's also designed to clear 17" wheels and the highest possible wheel offsets that won't hit the strut. Bigger wheels will just have more clearance.

Thats awesome! Looking forward to it. I would love to return brake cooling to my CSL Bumpered M3 again.

[Bry5on]

Oh Will this fit cars with OE CSL intake setup and CSL bumper?

This will fit all M3s, and will provide effective brake cooling for a car with a CSL bumper especially. It's also designed to clear 17" wheels and the highest possible wheel offsets that won't hit the strut. Bigger wheels will just have more clearance.

[0-60motorsports]

More rainy day projects, I started working on a brake duct that'll be much much better than the one I removed to install the CSL intake duct. Here's a first draft in CAD, and tomorrow afternoon I should have the prototype all printed up.

https://www.youtube.com/watch?v=m5zYhd987Ds

Oh Will this fit cars with OE CSL intake setup and CSL bumper?

[Bry5on]

More rainy day projects, I started working on a brake duct that'll be much much better than the one I removed to install the CSL intake duct. Here's a first draft in CAD, and tomorrow afternoon I should have the prototype all printed up.

https://www.youtube.com/watch?v=m5zYhd987Ds

[kaiv]

Progress continues..


After that insert as practice, I turned to the real project. A ZHP bumper brake duct to CSL airbox inlet duct and accordion flex boot. First I masked off the area to get some good measurements and a 3D scan with the iPhone faceid lidar sensor, which gave me the local area and surfaces I needed to route a duct:


Then off to the 3D printer for a first iteration. I used the entire build height of the printer, and actually needed a few mm more, so I nipped the top 5mm off of the printed part of the duct. You'll see below why this didn't really matter after installing the TPU printed flexible accordion boot. This is actually version 2:



It helped having an extra CSL flap to get dimensions, as this is an odd shape:


And after adding some mounting points to V3, we're in business. This piece uses two factory mounting points to secure in place along with the bumper opening to locate itself in 3D space. From there, the CSL airbox is installed from the top just as it is on the factory CSL. The flexible TPU piece in between has a groove that locks into the CSL flap just like stock, and is flexible enough to snap/pop in place on install. It also has double walls to locate on the duct itself to make sure it stays positioned, even as the engine vibrates at high revs. So, here it is:



You can see here how the flexible boot fully encompasses the section of print I had to notch out:

Incredible work Bryson! Can't wait to get mine! 😄

[Bry5on]

Well well well, it appears those BMW engineers really were on to something with that flap ducting.

Background: I have both the pre-and post-flap ducting connected (ie: with the flap closed I'm drawing air from behind the left side of the bumper, but not with any sort of ram effect). You can see the termination of the post-flap intake duct in some of the photos above.

Tonight, on my drive home, I datalogged at a reasonably constant speed and rpm (~3500rpm, 5th gear, ~65mph) a drive with the flap open (briefly), then closed, then open again. At this constant speed and engine load, I saw an 8*C (14*F) in 1 minute, 15 seconds, with most of the drop happening in the first 15-20 seconds. This is a rather impactful change! Definitely more than I expected, as I already had a low temperature air source and I didn't see this behavior before doing the duct.

In the stock CSL firmware in sport mode the flap opens at 3300rpm in gears 1, 2, 3 (41mph) and at 40mph in gears 4, 5, 6. Seems logical.

Vertical yellow bars in the datalog below are when the flap opened/closed.

[Will]

Amazing work! Thanks for documenting and sharing with us.

[Projecte46m3]

Doing god's work in here!!

[Bry5on]

Progress continues..

First, I picked up the isofix cover that I had retrimmed in some e46 natural brown leather that heinzboehmer and I came across a few months back, finally:


Up next, we move back to 3D printing. I managed to fit the bigger screen into the ash tray dimensions, as above, and added some USB-C CarPlay and charge ports while I was at it. I tried to capture a bunch of photos to give a sense of the lighting match. It's actually pretty damn good, but the camera really struggles to capture it the same way as your eyes.

Open:

Closed:





After that insert as practice, I turned to the real project. A ZHP bumper brake duct to CSL airbox inlet duct and accordion flex boot. First I masked off the area to get some good measurements and a 3D scan with the iPhone faceid lidar sensor, which gave me the local area and surfaces I needed to route a duct:


Then off to the 3D printer for a first iteration. I used the entire build height of the printer, and actually needed a few mm more, so I nipped the top 5mm off of the printed part of the duct. You'll see below why this didn't really matter after installing the TPU printed flexible accordion boot. This is actually version 2:



It helped having an extra CSL flap to get dimensions, as this is an odd shape:


And after adding some mounting points to V3, we're in business. This piece uses two factory mounting points to secure in place along with the bumper opening to locate itself in 3D space. From there, the CSL airbox is installed from the top just as it is on the factory CSL. The flexible TPU piece in between has a groove that locks into the CSL flap just like stock, and is flexible enough to snap/pop in place on install. It also has double walls to locate on the duct itself to make sure it stays positioned, even as the engine vibrates at high revs. So, here it is:



You can see here how the flexible boot fully encompasses the section of print I had to notch out:


And lastly, a bit less exciting, the bracket for the PDC and trailer modules showed up from Europe, so I dropped that in:


All in all, a solid update I think.

[Bry5on]

So I recently bought a 3D printer and I’ve been practicing by making smaller things to learn the ropes before I jump into printing the ZHP-CSL duct and isolator boot.

So far I’ve experimented with TPA, ASA and ABS. I expect ABS will be my most popular material, and to that end, here’s an ash tray insert that I designed to hold a smaller 1.54” screen, along with gauge.s circuit board and GPS receiver. A print just finished for the bigger screen version (which clears to the half millimeter basically everywhere) that might replace this one, but here’s how it looks so far:



Here’s the big one:

[Bry5on]

On to the next project - does anyone have a 3D scanner in the Bay Area so I can get these dimensions right?

[0-60motorsports]

I have the same rear view mirror and love it. Dont even care where i threw the oval one LOL

[Bry5on]

I was home with a cold this weekend, so I made myself useful by tackling a couple little projects.
1: I repaired my black 996 calipers with the same fix I did to the red ones by bonding in the loose pins




2: I disassembled my M3 mirrors and created a functional bench setup for auto-dimming, along with wire harnesses that will be trimmed to length




3: I pulled the roof rail trim off and double-stick taped it to mimic what the factory did. I used 1/8" (3.2mm) tape, where the factory looked like 2mm. It fit just fine as the land for the tape is 3-3.5mm, a wagon takes about 10 yards.

[Bry5on]

I love following your progress man, it’s like watching a rocket scientist lol

I really appreciate how skilled your are. Kudos.

Thank you! I really enjoy the process of learning and this project really helps keep the skills sharp (enough) because you can dig into so many different disciplines.

And I’ve got one more victory claim before the weekend is over. The front PDC retrofit is complete. It works great, but was a bit of a bear specifically to modify the bumper beam. Other than that, everything went together as planned with the wire harness routed down the passenger side of the car. Now I can give my back some rest.