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Old 11-10-2008, 07:50 PM   #95
Scooby Specialist
Member#: 110304
Join Date: Mar 2006
Location: Crestline, CA
2004 Volvo S60R
No more Subie


Alright, just to keep all of you folks up to date:

The sample is in the mail headed for DS1 Motorsports, so it should be there by the end of the week! Once Dylan gets a chance to get a look at it and test fit it, etc. I'll work with him on any final input he might have.

Just some notes on differences between the sample and the final production version:

-On the sample, the 2 strips of cross bracing were heated and then bent into an "x" pattern. On the final version, these will be coined in my press-brake to ensure uniform/consistant dimensions and a slightly sharper bend radius for athstetic purposes.

-There are spacers of various sizes that sit between the reinforcement and the case to allow the base plate of the reinforcement to sit in proper alignment with the case as well as to clear some external webbing. The prototype was tested with these not welded to the base plate, and Dylan's sample is the same. These will be welded to the base plate on the final version for ease of installation and added stregnth.

-The sample was shipped with 4 class 10.9 bolts and grade 8 washers. The production version will include the 4 bolts along with class 10.9 washers and 4 flanged (OEM shape) class 10.9 nuts.

-Paint quality will also be improved on the final product over the sample. I've done quite a bit of painting lately using the base coat that I've chosen in order to really dial in the right consistency. The sample was sprayed with just an acrylic lacquer base coat. The production version will use the same base coat for color, but will include a 2 part acrylic enamel clear coat for a tougher surface finish and better chemical resistance.
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Last edited by jhargis; 11-11-2008 at 12:50 PM.
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