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Faults, Fixes and DIY Please share your experience and knowledge with other members by contributing your own DIY, or by helping another member find the elusive fix!


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Old Mon, Oct-05-2009, 06:09:42 PM   #1
Jeppe
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Default DIY: Subframe reinforcement epoxy/foam method. e46

Here I will show you how I did the subframe reinforcement using epoxy glue to mount the turner subframe reinforcement plates. And then reinforcing the subframe using the BMW foam method. The good thing about this method is that you can do everything yourself and you don't need to weld your chassis which can cause rust problems later.

In the BMW TIS they only inject structuring foam on the left side. I did the right as well just to be on the safe side.

What you need:
---------------------------------
Turner subframe reinforcement plates
3M Epoxy Glue 08115 x1

BMW TIS download here: e46_subframe_tis.pdf
Cavity foam 83 42 9 410 694 x1
Structuring foam 83 42 0 307 530 (x2 if you want to reinforce the right side as well)

Thinner or similar for cleaning the surface

Applicator gun. One for the Epoxy and one for the foam. I made my own.
---------------------------------

The applicator guns are really expensive and you need two. So I made my own from a regular applicator gun. This can be used with both the epoxy and the foam cartridges. But you can probably borrow the guns from a body shop.





Here I have sanded the plates down using a angle grinder with sanding plate.


Subframe sanded down.


Test fitting the plates.


Apply the epoxy using this type of tool.


Epoxy applied on the car.


And on the plates.


Mount the plates and tighten the bolts. You should see some epoxy squeezing out evenly around the edge of the plate. Make sure you don't block the small drainage holes with epoxy.


Use your hands with rubber gloves to spread out the epoxy around the edge of the plate. This is how it should look.


Then let it dry for 24hours +. I let it dry for 48hours before I painted the plates with rust protective paint. Finished!


Then it's time for the foam. It's good to have a print of the BMW TIS when doing this.


First drill a hole in the middle between the holes that are already there. You can see that I have made cuts in the floor, this is not necessary when doing the foam method. I was going to do the welding, thats why its cut.


Here you can see the hole hiding underneath.


Then remove the sound deadening to find this hole.


If you plan on doing the right side as well you don't need to look for this hole on the right side. It isn't there, I have looked..




Then fill the two holes with cavity foam as explained in the BMW TIS. Make sure you empty out the rest of the can somewhere or else it will explode!


Preheat the structuring foam to about 60C in a water bath.


Wait 10min then inject the structuring foam as explained in the BMW TIS.


After injecting two cartridges of structuring foam into this hole. The foam expands a lot and fills up your subframe. Some foam will protrude out of this hole and the small drainage holes under the car. Inject two cartridges into the right hole also if you want to reinforce that side as well like I did.


Let it dry for 24hours. Car must not be moved during the hardening period.

Good luck!

Last edited by Jeppe; Wed, Dec-18-2013 at 08:42:53 PM.
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Old Mon, Oct-05-2009, 06:51:07 PM   #2
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Most excellent. Will be stickying this in the DIY section so it can be kept where people can find it!
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Old Mon, Oct-05-2009, 09:03:14 PM   #3
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Fantastic DIY! Congrats.
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Old Tue, Oct-06-2009, 12:45:19 AM   #4
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Jeppe! Thanks for this DIY bro! Now i can get it done on my car soon
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Old Tue, Oct-06-2009, 01:39:02 PM   #5
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Wow, excellent DIY. Where can we purchase the foam? I checked a few online sources like Tischer and didn't see those part numbers listed. Do we have to visit our dealer to get our hands on it?

I already have the Turner kit welded in however it does hurt to also inject the foam. It should stiffen up the rear as well.
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Old Tue, Oct-06-2009, 02:38:17 PM   #6
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how difficult would you say this is to do? this doesnt seem too difficult for the average weekend diy'er like me
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Old Tue, Oct-06-2009, 03:07:53 PM   #7
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Thanks guys, hope it helps.

Quote:
Originally Posted by likev View Post
Wow, excellent DIY. Where can we purchase the foam? I checked a few online sources like Tischer and didn't see those part numbers listed. Do we have to visit our dealer to get our hands on it?

I already have the Turner kit welded in however it does hurt to also inject the foam. It should stiffen up the rear as well.
Any BMW parts store should be able to order it for you. It's BMW part numbers. Otherwise try your dealer.

Quote:
Originally Posted by 00 XE7EN View Post
how difficult would you say this is to do? this doesnt seem too difficult for the average weekend diy'er like me
It's easy. The most difficult part is getting the subframe down if your doing the plates as well.
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Old Tue, Oct-06-2009, 03:46:30 PM   #8
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I contacted Tischer and they said, "NLA(No Longer Available) for US dealerships to order from BMW".
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Old Tue, Oct-06-2009, 03:53:30 PM   #9
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Quote:
Originally Posted by deilenberger View Post
Most excellent. Will be stickying this in the DIY section so it can be kept where people can find it!
i vote not to sticky it right away, otherwise it won't get the proper press it deserves
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Old Tue, Oct-06-2009, 05:34:45 PM   #10
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Quote:
Originally Posted by likev View Post
I contacted Tischer and they said, "NLA(No Longer Available) for US dealerships to order from BMW".
Hmm.. I ordered it from GS Bildeler here in Norway. The page is all in Norwegian but you can send them an e-mail. They can probably send you the foam.
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Discussing DIY: Subframe reinforcement epoxy/foam method. e46 in the Faults, Fixes and DIY Forum - Please share your experience and knowledge with other members by contributing your own DIY, or by helping another member find the elusive fix! at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)