Ever since I installed Stoptech ST40 brakes on my E46 330ci. (let's take a moment of silence for Stoptech) I was in search of a brake duct solution but all I could find were ducts on eBay that were purely cosmetic or quality kits that forced you to delete the fog light. Neither of which I was interested in.
So I decided to design my own using the power of a 3D scanner, CAD and my 6 brain cells running on too much caffeine.... oh and also a 3D printer.
Like most things in my life, I didn’t really have an idea of what it was going to look like or any inspiration for the design. I kind of just…started drawing and prototyping until I found something I liked.
And when I say I prototyped…I mean it. I probably went through 100 iterations and hundreds of dollars worth of filament to get to a final design that I liked.
I know the inevitable comment about 3D printing is going to come so I’ll just address here now: I have a background in engineering and material science (for my double digit IQ level that is shocking, I know). But with my background it ostensibly means that I understand a little bit about how to make something that is going to withstand its environment.
The material used for these ducts is ASA which has high impact toughness and UV resistant. “BUT WHY DIDN’T YOU USE CARBON FIB—“ shhhhh… things also need to be affordable. Could I have spent double the price and used PAHT-CF? Yeah. Would it make any difference in looks, performance or quality? No. (But to remain scientifically consistent, probably not.)
The final design uses organic and free flowing NACA duct-style geometry that forms around the fog light housing. It is one piece and wraps around the bezel of the M sport/ZHP fog light housing.
I had the option of designing it to fit with the OEM fog light trim piece but I decided against it. The reason? I know e46 owners. Most you guys who track your cars are running a rep m sport bumper that is held on with zips and prayers. So the likelihood of having the fog light trim piece is low. (No offence but I have to assess my demographic accurately).
The rear outlet side that goes to the brake rotors is 3.0 inches in diameter. This is the standard nominal size for brake piping that you will be using.
The hardest part about this design is that there are limited fastening spots in the bumper. So I resorted to 3M double sided tape and it’s held up for weeks now of really hard driving so I can safely say that problem is solved. Although I know someone is going to tell me to just send a self taper through my bumper and call it a day but I’m not hardcore enough for that.
I am working on developing backing plates that mount to the rear hubs and I will eventually be selling a complete kit that comes with everything needed to run this system.
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