Prototyping my Custom Wheel Spacers

[YBimmer]

Being a college student has it's perks... I have access to the Plastics Lab, where I play with carbon fiber and composites materials. But recently I have been interested in the suspension of my car.

After learning about clearance issues with coilovers, I searched out different spacers. Unsatisfied with the variability of the current spacers I designed some spacers specific to my situation. This is what I drafted in CAD and formed via Rapid Prototyping...

http://i718.photobucket.com/albums/ww188/my95bimmer/DSC_0356.jpg

http://i718.photobucket.com/albums/ww188/my95bimmer/DSC_0355.jpg

http://i718.photobucket.com/albums/ww188/my95bimmer/DSC_0357.jpg

I designed this prototype on my computer. This sample is a generic 12mm spacer in a 5x120 bolt pattern. I have drafted others in various thicknesses and with different hub bore/wheel bore diameters so I can go from the E36 72.56mm hub bore to the 74.1mm Style 5 wheel without the use of hubcentric rings.

The sample was developed by laying down successive layers of plastic on a Rapid Prototyping machine. This sample spacer was produced for the sole purpose of testing for fit and hole spacing before I have the actual spacer produced in aluminum on the CNC. This is all new territory for me, so if anyone has some suggestions or advice please share.

[2000mkoop]

Just do 4 in plastic, it'll work fine :D

Good idea, hope it works out good !

[Edison@Jlevi SW]

Cool stuff, rapid prototypers are fun :D What changes are you planning on the spacers?

[MrPedo]

wow thats bad ass!

[Mark@EAC]

cool project!

[Eddy@ApexRaceParts]

If that service wasn't free to you at school, that one plastic spacer right there would have paid for a lot of real aluminum ones lol. I just ogle thos machines every year when I'm at SEMA. 35k is a little pricey for my needs

FYI, I don't see what's functionally different with your design vs. what is currently available from most everyone.

[YBimmer]

Thanks for all the nice comments!


Cool stuff, rapid prototypers are fun :D What changes are you planning on the spacers?

The changes will all be determined after I get the bolts to my style 5's back from chrome plating. After I reassemble the wheels I will be able to measure the necessary spacing to get it as flush as I can without excessive rubbing. The spacers will also accommodate the larger bore size of the style 5's.


If that service wasn't free to you at school, that one plastic spacer right there would have paid for a lot of real aluminum ones lol. I just ogle thos machines every year when I'm at SEMA. 35k is a little pricey for my needs

FYI, I don't see what's functionally different with your design vs. what is currently available from most everyone.

Due to my sincere interest in cars some friends asked for help with their carbon fiber projects and I obliged to help during my free time. After seeing the possibilities available, I mocked up this spacer in about an hour before I went to work. My friends helped arrange to produce it free of charge. I'd never been in this part of the university and was curious how things worked. They've also offered to produce the aluminum copies for me, which means I can make my own spacers for free and to my liking. How many people can say they've done that?

You called it, it is a run-of-the-mill 12mm spacer... designed flawlessly. But, here is the kicker... I got the satisfaction out of knowing I made it. Currently I have been applying for medical school and had studied neuroscience and chemistry in college. Coming from a background where all I do is mix chemicals in a fume hood and work patients up in a hospital, that's a darn good feeling! Alteration will be determined within the next week. I'll keep you up to date.

[Evil Spoonman]

For no other reason than you took it upon yourself to create; I salute you. Wish you the best of luck with the project.

The spacers look quite well executed. Show us the aluminum ones once they're done!