Front Reinforcement Plate...in carbon fiber!

bigjae1976 · 12-21-2022, 04:45 PM

I was able to get an extra front plate in really good shape. Figured why not?

I made a front plate for my E46 track car. Tested for the last 8 months, it’s still working!

So I decided to make an E90 plate using an infusible core. So here it is…

8.2lbs vs 4.6lbs! It is about the same stiffness as the aluminum plate by my very unscientific test of standing on it.

bigjae1976 · 12-21-2022, 04:51 PM

I’m still working out the fasteners for the underbody panels and jack point. And then it will be time for a test fit tomorrow.

I need a 3” hole saw to cut out the front opening. I will test fit and see if it works as is. I think it should.

tsk94 · 12-21-2022, 05:07 PM

Nice!

Redd · 12-21-2022, 05:46 PM

Very nice! How do you reinforce the bolts holes so it survives being regularly removed and reinstalled without cracking/chipping?

Redd · 12-21-2022, 06:04 PM

Do you plan on selling these things?

bigjae1976 · 12-21-2022, 07:38 PM

Quote:

Originally Posted by Redd

Very nice! How do you reinforce the bolts holes so it survives being regularly removed and reinstalled without cracking/chipping?

As long as there is no core material then no reinforcement is needed. It will actually last longer than aluminum since the aluminum galls.

The attached pic is from my E46 plate which is 8 months old and has already been removed a couple of times.

Quote:

Originally Posted by Redd

Do you plan on selling these things?

Possibly. Didn’t think there would be much interest in this.

bigjae1976 · 12-21-2022, 07:42 PM

Plate is done! Test fit complete and hardware installed.

I installed the jack pad with some steel rivets I had laying around and then realized there is an OE part # for the rivets.

I used stainless rivet nuts to hold on the front engine screening.

okusa · 12-21-2022, 08:12 PM

Quote:

Originally Posted by bigjae1976

Possibly. Didn’t think there would be much interest in this.

Well...there is!!!

bigjae1976 · 12-21-2022, 09:22 PM

I like doing this so I would be willing to make more. I want to make one more and do some things differently. I used a core material except around the edges. I laid up 3 extra layers of 2x2 twill fabric between the bolt holes.

I want to use a unidirectional fabric between the bolt holes instead of a 2x2 twill which will add twice the stiffness vs a 2x2 twill at the same weight.

Once I decide on a final layup schedule then I can probably knock one out per week depending on availability of supplies.

///3dkn · 12-21-2022, 09:50 PM

Subscribed

rhyary · 12-21-2022, 10:09 PM

sub

spxxx · 12-21-2022, 10:36 PM

Subbed... Hell yes! I might be bugging you about CF projects, I'm in the research mode to get started fabbing some fiber parts.

bigjae1976 · 12-21-2022, 10:50 PM

I ran the numbers. Worst case here. If I can get at least 8 paid up, price would be around $900. The most I can do is 12, pricing would be around $800.

Even worth exploring?

DRLane · 12-22-2022, 09:34 AM

All is quiet on the western front…

NiBe · 12-22-2022, 12:09 PM

This is so cool!

94jedi · 12-22-2022, 06:16 PM

Quote:

Originally Posted by bigjae1976

I ran the numbers. Worst case here. If I can get at least 8 paid up, price would be around $900. The most I can do is 12, pricing would be around $800.

Even worth exploring?

Man that is really nice; e92 is different though, right? Or is it the same p/n?

I'd give this a very serious look if you produced a few more.

DRLane · 12-22-2022, 06:28 PM

Quote:

Originally Posted by 94jedi

Man that is really nice; e92 is different though, right? Or is it the same p/n?

I'd give this a very serious look if you produced a few more.

They should all be the same across e9x M3.

admranger · 12-22-2022, 11:21 PM

bigjae1976 doing some vacuum bag CF work. Brings me back to the autoclave days using frozen prepreg to layup B2 parts. That's some really cool work you've done. I'm impressed.

I probably still have carbon fiber slivers in me. Hate working with that stuff. Be careful cutting it. Use respiratory protection please.

The biggest problem with this is how would you show it off to your friends at cars and coffee?

XKxRome0ox · 12-23-2022, 12:28 AM

have no idea how any of this works but it's really cool that you can make your own CF part

bigjae1976 · 12-23-2022, 11:15 AM

Quote:

Originally Posted by admranger

bigjae1976 doing some vacuum bag CF work. Brings me back to the autoclave days using frozen prepreg to layup B2 parts. That's some really cool work you've done. I'm impressed.

I probably still have carbon fiber slivers in me. Hate working with that stuff. Be careful cutting it. Use respiratory protection please.

The biggest problem with this is how would you show it off to your friends at cars and coffee?

Thanks!

I wear a respirator, glasses, and coveralls. I probably should wear a full face. Right now, cutting CF is not bad at all. When its 100 degrees outside? Sucks balls. I have to do it outside because you don't want that stuff getting into the house.

It's not lost of me that a big reason for putting CF parts on is to impress other guys. Which is why I don't think this would be a big seller. But hey...I'll put it out there.

It usually goes...

Facebook Muscle Guy: Oh that's awesome, can you make more?
Me: Yes, I have the mold
Facebook Muscle Guy: How much?
Me: $1000
Facebook Muscle Guy: Bruh, can you do $300?

Quote:

Originally Posted by 94jedi

Man that is really nice; e92 is different though, right? Or is it the same p/n?

I'd give this a very serious look if you produced a few more.

I have a mold. $1000 for a one-off part.

reidetailing · 12-23-2022, 06:30 PM

This is really nice!
I was planning on getting a custom splitter that would replace the entire undertray and go back pretty far to I think the back of the engine.

Would I need to run both the splitter and this reinforcement plate?

bigjae1976 · 12-23-2022, 10:50 PM

Quote:

Originally Posted by reidetailing

This is really nice!
I was planning on getting a custom splitter that would replace the entire undertray and go back pretty far to I think the back of the engine.

Would I need to run both the splitter and this reinforcement plate?

You might be able to make it one piece but the splitter is probably going to be lower than the reinforcement plate. You probably want to make that two pieces for a lot of reasons - cost, serviceability, getting car onto tow trucks/trailers, but most of all when you damage the splitter its less costly to replace.

12-21-2022, 04:45 PM	#1
bigjae1976 Major General 1570 Rep 8,075 Posts Drives: 11 E90 M3 Individual Join Date: Mar 2006 Location: Houston, TX iTrader: (22) Garage List 2004 BMW M3 [4.50] 2011 BMW E90 M3 [5.25] 2013 BMW 328i [5.00]	I was able to get an extra front plate in really good shape. Figured why not? I made a front plate for my E46 track car. Tested for the last 8 months, it’s still working! So I decided to make an E90 plate using an infusible core. So here it is… 8.2lbs vs 4.6lbs! It is about the same stiffness as the aluminum plate by my very unscientific test of standing on it. Attached Images __________________ 2018 F30 320iX Melbourne Red 2011 E90 M3 Monte Carlo Blue 2004 E46 M3 Imola Red 2000 E36/7 Z3 Steel Blue
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12-21-2022, 04:51 PM	#2
bigjae1976 Major General 1570 Rep 8,075 Posts Drives: 11 E90 M3 Individual Join Date: Mar 2006 Location: Houston, TX iTrader: (22) Garage List 2004 BMW M3 [4.50] 2011 BMW E90 M3 [5.25] 2013 BMW 328i [5.00]	I’m still working out the fasteners for the underbody panels and jack point. And then it will be time for a test fit tomorrow. I need a 3” hole saw to cut out the front opening. I will test fit and see if it works as is. I think it should. __________________ 2018 F30 320iX Melbourne Red 2011 E90 M3 Monte Carlo Blue 2004 E46 M3 Imola Red 2000 E36/7 Z3 Steel Blue
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12-21-2022, 05:07 PM	#3
tsk94 Lieutenant Colonel 1522 Rep 1,591 Posts Drives: E92 M3, E82 128i, F82 M4, E36 Join Date: May 2017 Location: Calgary iTrader: (2)	Nice!
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12-21-2022, 05:46 PM	#4
Redd Brigadier General 3897 Rep 4,160 Posts Drives: 2010 BMW E92 M3 Dakar Edition Join Date: Jul 2015 Location: Malaysia iTrader: (0)	Very nice! How do you reinforce the bolts holes so it survives being regularly removed and reinstalled without cracking/chipping?
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12-21-2022, 06:04 PM	#5
Redd Brigadier General 3897 Rep 4,160 Posts Drives: 2010 BMW E92 M3 Dakar Edition Join Date: Jul 2015 Location: Malaysia iTrader: (0)	Do you plan on selling these things?
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12-21-2022, 07:42 PM	#7
bigjae1976 Major General 1570 Rep 8,075 Posts Drives: 11 E90 M3 Individual Join Date: Mar 2006 Location: Houston, TX iTrader: (22) Garage List 2004 BMW M3 [4.50] 2011 BMW E90 M3 [5.25] 2013 BMW 328i [5.00]	Plate is done! Test fit complete and hardware installed. I installed the jack pad with some steel rivets I had laying around and then realized there is an OE part # for the rivets. I used stainless rivet nuts to hold on the front engine screening. Attached Images __________________ 2018 F30 320iX Melbourne Red 2011 E90 M3 Monte Carlo Blue 2004 E46 M3 Imola Red 2000 E36/7 Z3 Steel Blue
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12-21-2022, 09:22 PM	#9
bigjae1976 Major General 1570 Rep 8,075 Posts Drives: 11 E90 M3 Individual Join Date: Mar 2006 Location: Houston, TX iTrader: (22) Garage List 2004 BMW M3 [4.50] 2011 BMW E90 M3 [5.25] 2013 BMW 328i [5.00]	I like doing this so I would be willing to make more. I want to make one more and do some things differently. I used a core material except around the edges. I laid up 3 extra layers of 2x2 twill fabric between the bolt holes. I want to use a unidirectional fabric between the bolt holes instead of a 2x2 twill which will add twice the stiffness vs a 2x2 twill at the same weight. Once I decide on a final layup schedule then I can probably knock one out per week depending on availability of supplies. __________________ 2018 F30 320iX Melbourne Red 2011 E90 M3 Monte Carlo Blue 2004 E46 M3 Imola Red 2000 E36/7 Z3 Steel Blue
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12-21-2022, 09:50 PM	#10
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12-21-2022, 10:50 PM	#13
bigjae1976 Major General 1570 Rep 8,075 Posts Drives: 11 E90 M3 Individual Join Date: Mar 2006 Location: Houston, TX iTrader: (22) Garage List 2004 BMW M3 [4.50] 2011 BMW E90 M3 [5.25] 2013 BMW 328i [5.00]	I ran the numbers. Worst case here. If I can get at least 8 paid up, price would be around $900. The most I can do is 12, pricing would be around $800. Even worth exploring? __________________ 2018 F30 320iX Melbourne Red 2011 E90 M3 Monte Carlo Blue 2004 E46 M3 Imola Red 2000 E36/7 Z3 Steel Blue
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12-22-2022, 09:34 AM	#14
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12-22-2022, 12:09 PM	#15
NiBe First Lieutenant 453 Rep 365 Posts Drives: BMW E91 & E92 Join Date: Nov 2021 Location: Europe iTrader: (0)	This is so cool!
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12-22-2022, 11:21 PM	#18
admranger Retired Curmudgeon 2985 Rep 4,047 Posts Drives: ‘19 X3M40i, ‘18 m550i Join Date: May 2011 Location: Las Vegas, NV iTrader: (1)	bigjae1976 doing some vacuum bag CF work. Brings me back to the autoclave days using frozen prepreg to layup B2 parts. That's some really cool work you've done. I'm impressed. I probably still have carbon fiber slivers in me. Hate working with that stuff. Be careful cutting it. Use respiratory protection please. The biggest problem with this is how would you show it off to your friends at cars and coffee? __________________ '19 X3 M40 Carbon Black/Oyster, '23 Jeep Grand Cherokee L Summit, Past BMWs: '18 M550i, '18 330 GT, '16 X5 40e, '11 E90M3, '06 X5 4.4, '03 330i ZHP, '02 M3, '97 Z3 2.8, '95 M3 (2x), '94 530i (manual), '92 525i (manual), '88 M3, '87 325iS Last edited by admranger; 12-22-2022 at 11:26 PM..
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XKxRome0ox e90noob 1588 Rep 1,862 Posts Drives: '08 E90 M3 Join Date: Mar 2012 Location: Los Angeles, CA iTrader: (4)	have no idea how any of this works but it's really cool that you can make your own CF part __________________ 2008 E90 M3 / LCI trunk + euro tail swap Production date - 2008-04-22
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12-23-2022, 06:30 PM	#21
reidetailing Alex - IG @screamer 601 Rep 472 Posts Drives: 08 SS E90, 11 Moonstone E92 Join Date: Feb 2019 Location: Toronto iTrader: (7)	This is really nice! I was planning on getting a custom splitter that would replace the entire undertray and go back pretty far to I think the back of the engine. Would I need to run both the splitter and this reinforcement plate? __________________ Instagram: @screamer - 2013 Subaru STi Hatch - White - Racecar - 2011 BMW E92 M3 - Moonstone - Collector Car - 2008 BMW E90 M3 - Silverstone - Racecar
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