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Thread: I'm fabbing up a tow bar for my car

  1. #1
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    I'm fabbing up a tow bar for my car

    I've been tossing around the idea of buying a truck or installing a tow bar on the car. The mrs wasn't too keen on the truck thing, so here we are with the tow bar. Over the weekend I purchased a Harbor Freight trailer. It was $350 and they seem to have great reviews.

    I decided to go with a modified Witter design since it had the most research info available to me. It's not complete yet, but I'll post pics as I make progress.

    diagram.png

    My mock-up so I can get an idea of the tongue height.

    20200125_154814.jpg


    20200127_170632.jpg

    20200127_104815.jpg


    20200127_170628.jpg
    2003 540i/6

  2. #2
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Andy, I think Philly made one too.

    I see you have a WEN drill press. I bought that same one 2 weeks ago.
    Last week I ordered an X-Y table and a bunch of milling bits for it, they came today. Haven't had time to play around with it, just got back from 6 days in TX.

  3. #3
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    It's the 12" (4214) and I've got the 4.25" compound cross slide vise (414CV). 90% of the time the vise is large enough, but there are times I wish I had the larger vise. I really like the drill press, but it's not without its faults. There's a little tiny bit of run-out and the bit sometimes wants to walk. Most of the time it drills fine, but I've drilled a few holes that were off about 0.015 (1/64"), which I guess is usually not an issue.

    I've tried putting a lateral load on the drill press and the chuck kept falling out. I was trying to use it as a lathe by turning a groove in a rod for a retaining ring. That being said, I don't know if the end mills are going to work out very well. You'll probably have to get a Bridgeport

    It looks like you can pick up a small milling machine for about a grand. I could see that coming in handy, but I'm the guy that bought a CNC router and did nothing with it for 2 years before selling it.
    2003 540i/6

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    JimLev's Avatar
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    Was just getting ready to check the runout. I did drill a few 1/2" holes, they were fine.
    I haven't had any problem with the chuck, did you clean both parts and then drive it in like the manual said too?
    One thing I didn't like was the slop in the vertical adjust for the table. I fixed it using some washers as shims.
    Umm, a CNC router, I'll have to look into that.

    Dscn4010.jpg

    Dscn4011.jpg

    My X-Y table. I'm only going to be milling aluminum to make a few parts for the hotrod. Nothing critical as far a dimensions go.
    I bought a 4 x 8 sheet of stainless to make a top and sides for my latest tool box.

    DSCN4013.JPG

  5. #5
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    I know mine is a wagon but if you want I can see if I can get some pictures on how they did it at the factory when I am back with the car this weekend. This is what, I'm assuming, a stock tow hitch should look on an e39 (picture is from a previous owner in 2009, wish I had a better pic)
    Attached Images Attached Images

  6. #6
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    The original hook is made by Oris or Westfalia and labeled BMW. It's detachable with a slide in and lock mechanism on the hook itself. The body itself is made out of Al. It has a module that cuts off the pdc when the plug is connected.
    A thread and some pictures in it.

    http://bimmersport.co.nz/topic/48640...0i-motorsport/

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  7. #7
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    Quote Originally Posted by JimLev View Post
    I haven't had any problem with the chuck, did you clean both parts and then drive it in like the manual said too?
    One thing I didn't like was the slop in the vertical adjust for the table. I fixed it using some washers as shims.
    Umm, a CNC router, I'll have to look into that.
    Man, that's a good idea for the vertical adjustment. The chuck stays in just fine if you use the drill press as it's meant to be used, but once you start putting a side load on, the chuck may fall out. I got fed up with it and learned how to use the lathe at work. My router was marketed as an engraver. It was one of those cheap Chinese engravers from ebay.

    Some guys on the CNCzone forum were able to get theirs to mill aluminum, but it looked like a lot of effort and I wasn't that interested at the time. The only cool part about the CNC engraver/router is the CNC part, but I work with CAD all day at work, so coming home and creating toolpaths isn't my idea of a good time. I do think one of those manual bench top CNC machines would be nice to have though.
    Here's a video of mine doing a relief carving on some MDF. I pretty much bought the machine, set it up, built a sound proof enclosure, fine tuned it, and let it sit there.



    Quote Originally Posted by mateo8 View Post
    I know mine is a wagon but if you want I can see if I can get some pictures on how they did it at the factory when I am back with the car this weekend. This is what, I'm assuming, a stock tow hitch should look on an e39 (picture is from a previous owner in 2009, wish I had a better pic)
    Quote Originally Posted by taz. View Post
    The original hook is made by Oris or Westfalia and labeled BMW. It's detachable with a slide in and lock mechanism on the hook itself. The body itself is made out of Al. It has a module that cuts off the pdc when the plug is connected.
    A thread and some pictures in it.
    http://bimmersport.co.nz/topic/48640...0i-motorsport/
    Good info, thanks. The part I'm probably going to have trouble with is this...
    post-373-0-94752500-1395694814.jpg

    I'm going to be using the standard 1.25" Class II square tube/bar, so my receiving tube might not be able to be hidden behind the cover. (I bought the hitch diffuser and cover, but they're not shipping until Feb 10)

    diffuser.JPG

    I also bought both of these to see which one might work out better.

    hitches.png

    concept.JPG

    I've eyeballed and cut out where I think the cover will go so I can keep working, but I really think the receiver is going to be visible.

    mydiffuser.JPG
    Last edited by waters17; 01-30-2020 at 09:39 AM.
    2003 540i/6

  8. #8
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    Not sure if I did a thread, but some pics of the one I did in this thread. Looks like you got a similar plan!!

    https://www.bimmerforums.com/forum/s...-cross-country

    mine is super sturdy! Yours should be too. Happy welding
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  9. #9
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    Quote Originally Posted by philly98540 View Post
    Not sure if I did a thread, but some pics of the one I did in this thread. Looks like you got a similar plan!!

    https://www.bimmerforums.com/forum/s...-cross-country

    mine is super sturdy! Yours should be too. Happy welding
    Awesome! Yeah, it looks like I'm headed in the same direction. I have a question for you though.

    How thick are the plates that go to the receiver? I was thinking of using 3/8", but it looks like 1/4" would do it.
    philly.JPG
    2003 540i/6

  10. #10
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    Those plates came on the euro hitch already. Iirc like 6mm plate but may have been thicker. 1/4 should do it but 5/16 or 3/8 to be safer.
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  11. #11
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    Quote Originally Posted by philly98540 View Post
    Those plates came on the euro hitch already. Iirc like 6mm plate but may have been thicker. 1/4 should do it but 5/16 or 3/8 to be safer.
    Cool, thanks.
    2003 540i/6

  12. #12
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    Guys don't make too sturdy, the original is aluminum, made to absorb the impact in case of a rear end collision. Remember you will be removing the bumper shocks ment to take the impact. The aftermarket one is made out of steel, strong and heavy and in case of an impact it will bend the rails. Ask me how I know!!!

    Me and the culprit at a speed of 20km/h, just after the traffic lights.

    It bent my rails and the back panel.
    Insurance didn't want to pay, so...

    Now I got the original hook, al, light and ment to deform.
    Keep this in mind

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  13. #13
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    Good info!

    Now that you mention it, I'm wondering if that's why these parts are so wimpy. I imagine that they would bend on impact.
    bend.JPG
    2003 540i/6

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    Precisely, also the assembly bar should be deformable, mine was thick steel and still it got bent to the point of being just garbage.
    The Oem assembly bar is lighter then the hook itself, maybe 5kg whilst the AM was min 20kg.
    I don't think you're gone towe Godzilla, and the aluminum Oem was rated up to 2t

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  15. #15
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    The tow bar is complete! I just need to finish up the wiring and I'll be ready to tow. I broke my bumper cover when I was doing a test fit. One of the black plastic fasteners was still lodged in the aluminum bumper and it got stuck on one of the tabs on the bumper cover as I was removing it from the car. You can see where it broke -near the tow hook door. I'm still waiting on ECS to ship my diffuser parts. I also need to wash my car.

    Don't mind the rust, I plan on doing a little body work this spring.

    000.JPG


    Welded and painted. I'm not big on cleaning up weld berries.
    001.JPG


    002.JPG


    004.JPG


    005.JPG
    2003 540i/6

  16. #16
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    Looking good! Nice and tucked in.
    98 540i 6, 525 whp, 120 mph 1/4, V3 Si S/C'er @16 psi, W/A I/C, Water/Meth, Supersprint Headers, HJS Cats, 3" Custom Exhaust, UUC Twin Disc, Wavetrac LSD, GC Coil Overs, Monoball TA, AEM FP, Aeromotive FPR, AEM Failsafe AFR/Boost, Style 65's w/275's, M5 Steering Box, Eibach Sways, M3 Shifter, Evans Coolant, 85 Deg Stat, PWM Fan, 10" Subs, B.A. speakers, Grom Aux/BT, Still Rolling as my DD!

  17. #17
    JimLev's Avatar
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    Good job Andy.

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    Thanks guys! I just hope it doesn't tear itself off while driving home with a load of drywall.
    2003 540i/6

  19. #19
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    Looks nice, clean and sturdy, I'll bet a Jack that it will tow at leat 2t.

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    nice, ive always considered doing this so i could tow my motorcycle,

  21. #21
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    Quote Originally Posted by taz. View Post
    Looks nice, clean and sturdy, I'll bet a Jack that it will tow at leat 2t.
    Thanks! The trailer maxes out at 1,195 lbs.


    Quote Originally Posted by MD540iT View Post
    nice, ive always considered doing this so i could tow my motorcycle,
    You should.
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  22. #22
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    Man! You did a really good job fabbing that tow hitch up!!! Now you got me thinking about doing one for my wagon..... like I really needed another project....
    Set the controls for the heart of the sun

  23. #23
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    Quote Originally Posted by BimmrMeUpSnotty View Post
    Man! You did a really good job fabbing that tow hitch up!!! Now you got me thinking about doing one for my wagon..... like I really needed another project....
    Thanks!

    EVERYBODY NEEDS A TOW HITCH!!!

    Also, that Harbor Freight trailer is on sale for $270 this month. I paid $350, but was able to use the coupon a week later and get the difference back.
    2003 540i/6

  24. #24
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    The maiden voyage was a success, so I figured a final pic was in order.

    maidenvoyage.JPG
    2003 540i/6

  25. #25
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    Looks pretty darn good Andy.

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