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Discussion Starter #1
Just finished it a couple of days ago. The brackets are 1020 steel plate machined on a manual mill, the tubing is 4130 chro-moly steel. Black textured semi-gloss powdercoated finish. One-piece, TIG welded, fully rigid constrution. While it's not super-bling looking, I figured that some of the more performance-oriented fanatics might appreciate this one, given the recent hype over strut braces.

<img src="http://www.stanford.edu/~merkuron/images/struttronic-small.jpg" border="1" bordercolor="#000000">
 

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Big in Japan
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Very nice sir! I love to see people take the initiative, it looks great.

You actually have hte strongest design there, except it only fits your car (there are variances, hence no one piece bar exists)

I have to ask though, wouldn getting the m3 bar have been easier?
 

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Discussion Starter #3
Hey RichP, thanks for the kudos. I'm fully aware of the variances, and I don't plan to mass-produce at all. Yes, the M3 bar would have been easier, would have cost about the same amount, and would be lighter, but I actually built this for a manufacturing & design class here at Stanford. So not ony do I have a brand-spanking new functional strut brace, but I also got credit for it. :)
 

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The OG Black Roof
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I love it!!!!!!

That is so awesome bro...It is very cool to see someone do that...And it looks like you've got some skill there..

Very nice work

:thumbup: :pimpin:
 

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E46Fanatic
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Nice job bro! I really like the way it looks. looks like the car came that way. simple, clean, and functional :thumbup:
 

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Discussion Starter #12
Thanks for the props everyone!

Kev, still waiting on that.

Garrett, it weighs about 8 pounds. As RichP and I mentioned before, it would be impractical to mass-produce something of this design. Nevertheless, it would be nice to hear comments from an experienced engineer!
 

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needs a new sig...
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Karl said:
Thanks for the props everyone!

Kev, still waiting on that.

Garrett, it weighs about 8 pounds. As RichP and I mentioned before, it would be impractical to mass-produce something of this design. Nevertheless, it would be nice to hear comments from an experienced engineer!
I absolutely understand why it would be really hard to mass produce them, as you do i would like to hear a response from someone else who recently designed a bar.
 

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If you don't mind my asking, how much did it cost, materials and number of hours of labor. Given the simple construction of these bars I've always wondered what they cost to make.

Thanks,
Adam
 

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Discussion Starter #18
It's unfair to gauge pricing for a one-off versus a volume production, but the approximate cost breakdown for this prototype was:

Materials - $130 (Shipping killed me on this one)
Tools - $100
Powder Coating - $85

Mill time - 16 hours
Tube cutting/fitting - 1 hour
Weld time - 1 hour (plus ~12-16 hours practice)
 

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I am an experienced engineer and that looks pretty good. The overall structure can only be stiffer than it was. The welds look really good. You estimate "practice time" in your last post like you just learned to weld; if you did just learn, then that is great for a rookie. :thumbup: The "hands-on" approach to modding is much more rewarding.

*I also have a custom strut tower brace, pix to come*
 

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Discussion Starter #20
325seeeye said:
I am an experienced engineer and that looks pretty good. The overall structure can only be stiffer than it was. The welds look really good. You estimate "practice time" in your last post like you just learned to weld; if you did just learn, then that is great for a rookie. :thumbup: The "hands-on" approach to modding is much more rewarding.

*I also have a custom strut tower brace, pix to come*
Thanks for the compliments! Yes, the DIY route is definitely the way to go, and sometimes DIY goes much deeper than most people care to go :).
 
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