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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 Sat, Aug-29-2015, 04:08:08 PM   #1
HassanEido
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Default New cracks after reinforcement

Was changing muffler hungers today, front wheel bearing,rear shock mounts, and oil.. Good right? Well to my horror, I found cracks where the subframe meats the wheel well in the back, both left and right, and a Crack near the spring mounts... Needless to say I'm gutted absolutely gutted
crack left.jpg
hairline near spring.jpg
horizonalcrack.jpg
Edit to add my conclusions:
I did not create this thread to cause panic. All I wanted to do was raise awareness:
-If u got cracks, check ur boot floor, I didn't. I just welded plates in and we checked the bottom of the car only, because we didn't know better hairline cracks might have already been there, but we didn't think to check there.
-when u check ur boot floor, check the spot welds on the front and rear mounts, chances are some are broken)popped, which led to the cracks below (root cause of all this crap) reinforce them.
- I did Not have foam either, only plates! I would imagine if I had foamed or filled my racp with resin, perhaps I wouldn't have seen this failure at all, although the resin doesnt reinforce the points where the racp meets the wheel wells or chasse, it simply reinforces the rcap itself, so only time will tell for those with this setup.
- Once u've done all this,or if indeed ur car was intact, get the x bracing action in the back and plates below, and never worry again.
-Once you have exposed the rcap floor, stitch weld the where the fender wells meet the rcap, cracks need to be stop drilled by 1-2 millimeter drill bet and welded. Popped spot welds csn be redone with rosette welds, I chose to stitch weld and do rosettes.
- The shop I worked with this time does race cars and hillclimb m3, what he did was a custom xbracing between the front and rear mounts of the rear subframe and then this x brace was tied down to the frame rails inside the rcap,and from the top tied to the shock towers
-A final note: take it to a prof! Hopefully this thread and others that have been so kindly started by others before me like Vince and the aircraft engineer who both reinforced their racp,hopefully these will help u know what needs to be done,and whether or not the shop that's doing the job knows their sh!t or not
This is what the custom brace looked like :
IMG-20150903-WA0003.jpg

Last edited by HassanEido; Thu, Sep-03-2015 at 04:51:46 PM.
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Old Sat, Aug-29-2015, 04:26:31 PM   #2
bimmerfan08
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Default Re: New cracks after reinforcement

Pictures?
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Old Sat, Aug-29-2015, 04:27:46 PM   #3
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Default Re: New cracks after reinforcement

I'm really sorry for you. Hang in there bud, after all it's just metal and paint.

This unfortunately shows that just reinforcement plates and/or "foam" does nothing to relieve the RACP from transferring the load to the frame rail.
You really need a Mason bar with the xbrace, or something like what I did.

















And don't forget the front mounts





Please let me know i can help you in any way.
This issue sucks!


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Old Sat, Aug-29-2015, 04:37:34 PM   #4
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Default Re: New cracks after reinforcement

Very sorry to hear this OP. I personally know the frustrations of these exact problems.

So much so that i had a custom rear bar connecting the shock towers, through the subfloor much like what the gentleman above me did. Good luck....







Trunk floor painted







The more reinforcements on this car the better IMO
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Quote:
Originally Posted by John_T View Post
Rules of life:

-As long as your are trying, chasing, longing, pawing, everything runs away.

-When you start minding your own business, doing what fulfills you and you enjoy the most, things may start coming to you... as long as you don't have expectations of them, think you are entitled to them.

A butterfly lands on your hand
Close it, you crush it
Leave it open, it may stay or fly away
But you have been blessed for the moments
Be grateful
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Old Sat, Aug-29-2015, 04:39:30 PM   #5
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Default Re: New cracks after reinforcement

You guys are right, all these plates are doing, is transfer the twisting forces elsewhere.. Thanks for the suggestions.. Now I'll have to splash some more cash or a custom brace and a subframe repair job.. I added pictures in my original post.. My weekend is ruined..

Last edited by HassanEido; Sat, Aug-29-2015 at 04:42:33 PM.
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Old Sat, Aug-29-2015, 04:40:57 PM   #6
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Default Re: New cracks after reinforcement

Didnt they go to a new floor pan, a slightly thicker one?

that is what the work order on my dealer fix says, even has a part number

sucks though bro.
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Old Sat, Aug-29-2015, 04:47:58 PM   #7
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Default Re: New cracks after reinforcement

I may be wrong but i feel as if the "new" floor pan you are referring to is the verts subfloor which was slightly thicker.
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Quote:
Originally Posted by John_T View Post
Rules of life:

-As long as your are trying, chasing, longing, pawing, everything runs away.

-When you start minding your own business, doing what fulfills you and you enjoy the most, things may start coming to you... as long as you don't have expectations of them, think you are entitled to them.

A butterfly lands on your hand
Close it, you crush it
Leave it open, it may stay or fly away
But you have been blessed for the moments
Be grateful
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Old Sat, Aug-29-2015, 04:50:04 PM   #8
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Default Re: New cracks after reinforcement

OP, honestly it seems as if you are looking at a new floor pan. Some of those cracks are pretty long, twisted and frayed. If you recently had the plates installed, the shop didn't see this??? These do not seem like new cracks by a long shot.
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Quote:
Originally Posted by John_T View Post
Rules of life:

-As long as your are trying, chasing, longing, pawing, everything runs away.

-When you start minding your own business, doing what fulfills you and you enjoy the most, things may start coming to you... as long as you don't have expectations of them, think you are entitled to them.

A butterfly lands on your hand
Close it, you crush it
Leave it open, it may stay or fly away
But you have been blessed for the moments
Be grateful
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Old Sat, Aug-29-2015, 04:56:31 PM   #9
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Default Re: New cracks after reinforcement

Guys - these pictures do not show RACP failure, which is what plates fix. Rather, we're seeing the REAL problem as far as I'm concerned - the RACP is pulling away from the chassis. No plate will address this - exacerbate if anything.

Only permanent fix is what the two guys above did.

I've got signs of this separation in my current car and even though I did plates and fixed the separation I'm still easy on it until I do the above method.
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Last edited by EricSMG; Sat, Aug-29-2015 at 05:00:20 PM.
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Old Sat, Aug-29-2015, 04:56:54 PM   #10
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Default Re: New cracks after reinforcement

I was under the car a 3 weeks ago...and I can promise u, these weren't there, I'm just gutted..

Last edited by HassanEido; Sat, Aug-29-2015 at 05:06:34 PM.
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Discussing New cracks after reinforcement 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)