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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Tue, Feb-26-2019, 04:16:34 PM   #21
bryce2113
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Default Re: Directory of 3D parts to DIY 3D print/machine

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Originally Posted by Drewster View Post
Here's my current - and I can't emphasize this enough - work in progress.

Shape is pretty much there, mounting may change

https://www.thingiverse.com/thing:3453651
Very helpful, thanks. Is this file just for the passenger side? I'll give it a go and report back.

I'm still contemplating how I want to mount the ducts. I like Obi's version of mounting to the frame/crash support for easy bumper removal. I'm also toying with making a version that replaces the fog lights. Essentially a duct that clips into the factory mounts for the fog lights.
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Old Tue, Feb-26-2019, 05:57:50 PM   #22
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Default Re: Directory of 3D parts to DIY 3D print/machine

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Very helpful, thanks. Is this file just for the passenger side? I'll give it a go and report back.

I'm still contemplating how I want to mount the ducts. I like Obi's version of mounting to the frame/crash support for easy bumper removal. I'm also toying with making a version that replaces the fog lights. Essentially a duct that clips into the factory mounts for the fog lights.
If you flip it in your slicer it *should* fit the driver's side, but that file is for the passenger (US).

I was messing with it last night, and the top *barely* clears the bumper mount/ frame, but the mounting holes are probably a bit too far back.

I'm going to try moving the mounts forward about 4cm which should make it easy to have a bracket coming off the stock duct mount, but depending on how picky you are it might be rivet-able to the bumper as-is. If you print it, I'm curious to see your feedback since the fitment is probably slightly different on each car.
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Old Thu, Feb-28-2019, 08:23:23 PM   #23
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Default Re: Directory of 3D parts to DIY 3D print/machine

Any designs better then using tennis balls?
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Old Thu, Feb-28-2019, 09:31:50 PM   #24
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Default Re: Directory of 3D parts to DIY 3D print/machine

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Any designs better then using tennis balls?
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Old Wed, Mar-20-2019, 04:59:08 PM   #25
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Default Re: Directory of 3D parts to DIY 3D print/machine

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Originally Posted by Drewster View Post
If you flip it in your slicer it *should* fit the driver's side, but that file is for the passenger (US).

I was messing with it last night, and the top *barely* clears the bumper mount/ frame, but the mounting holes are probably a bit too far back.

I'm going to try moving the mounts forward about 4cm which should make it easy to have a bracket coming off the stock duct mount, but depending on how picky you are it might be rivet-able to the bumper as-is. If you print it, I'm curious to see your feedback since the fitment is probably slightly different on each car.
Going to give this a try! Are the mounting holes the circular protrusions?

Any adjustments you think it might need? I can make those before I try the first print.
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Old Thu, Mar-21-2019, 03:26:55 PM   #26
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Default Re: Directory of 3D parts to DIY 3D print/machine

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Going to give this a try! Are the mounting holes the circular protrusions?

Any adjustments you think it might need? I can make those before I try the first print.
Just the mounting adjustments I mentioned! Some support might not hurt under the large ramp to the outlet, if your printer can swing it
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Old Fri, Aug-09-2019, 03:23:37 PM   #27
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Default Re: Directory of 3D parts to DIY 3D print/machine

Here's the brake ducts I came up with, which are designed to replace the stock foglights and OE brake ducts.

There's two variants-- one with an intake duct, one without. That said. I designed it with my intake setup specifically in mind-- so if you are running a stock intake or full stock ducting CSL intake, you'll need to tweak them to work with your setup. I included a ducted passenger version, as well, but that'll only be useful for engine swapped cars

The mounting brackets (files also attaches) should be metal. They attach to stock holes on the bumper, and you can use them at the same time as the stock parts that attach there (horns on the drivers side, I forget what on the passenger side).

The inside of the ducts mounts to the stock brake duct mounting location, reusing the stock hardware.

If you run the piping as pictured below, you should have zero rubbing at full steering lock (at least with my 275 wide front track tires that's the case for me). I used hard motorsport backing plates, but they're kind of crap-- I don't recommend them, but they do function with some massaging.

These are designed so that you can take the bumper off and the brake ducts stay behind-- so the car doesn't become more of a PITA to work on. They don't require drilling any holes in the bumper, or permanent modification to anything. That said, you get a clearly final look if you cut off the fog light mounting bracket inside the bumper.

You can download them all from dropbox here:
https://www.dropbox.com/sh/b5c0f5uzh...KUbzxduua?dl=0

here's the part, this is the ducted version:



Here's how they look installed with the bumper off:



bumper on with fog light mounting bracket retained:



Where's to pass the tubing through for no rubbing:



Full lock one way:



Full lock the other way:



Final result:



FWIW, YMMV
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Last edited by Obioban; Fri, Aug-09-2019 at 03:27:18 PM.
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Old Fri, Aug-09-2019, 03:47:41 PM   #28
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Default Re: Directory of 3D parts to DIY 3D print/machine

What is the print time for a single brake duct? Also what are the approximate dimensions, like how big a printer is needed?
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Old Fri, Aug-09-2019, 04:00:34 PM   #29
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Default Re: Directory of 3D parts to DIY 3D print/machine

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What is the print time for a single brake duct? Also what are the approximate dimensions, like how big a printer is needed?
Depends on the printer, but mine took ~60 hours each.

They're ~14" x 12.5" x 5"
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Old Fri, Aug-09-2019, 04:04:12 PM   #30
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Default Re: Directory of 3D parts to DIY 3D print/machine

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Originally Posted by Obioban View Post
Depends on the printer, but mine took ~60 hours each.

They're ~14" x 12.5" x 5"
I'm going to give these a shot. What material did you end up printing with?

Last edited by bryce2113; Fri, Aug-09-2019 at 04:09:41 PM.
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Discussing Directory of 3D parts to DIY 3D print/machine in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)