DIY - custom brake ducts for under $100 - BMW 1 Series Coupe Forum / 1 Series Convertible Forum (1M / tii / 135i / 128i / Coupe / Cabrio / Hatchback) (BMW E82 E88 128i 130i 135i)

BerkTechnology · 11-13-2009, 12:59 AM

This is a quick DIY for those of you who want to make a real set of brake ducts.

Prerequisites are:

A) You have at least two full days of free time.
B) You can fabricate basic things out of metal
C) Welding skills
D) You track your car on a regular basis. If you are a street guy then the OEM brake ducts (if you could call them that) are working fine for you.

Materials needed:
Silicone or nomex ducting 2.5" or 2" will work fine.
scrap 20 gauge sheet metal
scrap 16 gauge sheet metal
scrap 2.5" or 2" steel tubing
hose clamps
lots of zip ties

1. Remove caliper and rotor. The rotor is held in with a large philip screw. If you didn't know that's the one shaped like a "plus" sign then stop now.

2. Remove the OEM dust shield. It's bolted in with a few bolts.
3. Remove inner splash guard.
4. Remove OEM plastic ducting completely on driver side.
5. Partially remove plastic ducting on passenger side. You'll need to keep the ducting for the OEM oil cooler in tact. We don't want to mess with that as BMW did a good job in the air ducting to that little cooler. They didn't do such a great job in sizing that cooler though.
6. Fabricate backing plates using the 16 gauge steel as your base. Drill a hole and place your inlet hose as close to the center of the rotor as possible.
7. Fabricate a new mounting plate for the air inlet at the front bumper. Use the OEM mounting tabs that held in the OEM brake ducting to hold your new plate in place.
8. Route the hose as needed to clear all of the suspension pieces. Make sure to turn the wheels from full lock both ways to make sure you don't have any binding going on.

Your end result will look something like this.

The Rotora 355mm BBK is optional!

Have fun! PM me if you guys have any questions. Always here to help the DIY guys out!

Jettafanatic · 11-22-2009, 11:56 AM

You can use this instead and modify / rivet it to the backing plate / intake plate (a little more expensive though)

Ora cheaper / no weld ( still rivet ) way:

http://www.aircraftspruce.com/catalo...uctflanges.php

( I used these on my ducts on a racing jetta I had... )

Nice job Guys!

Ruffan · 01-15-2010, 10:35 AM

Has anyone done something like the suggestion above from Jettafanatic?

Alow · 04-30-2010, 12:54 PM

Berk,

I'm no expert, but I have never seen the 180 degrees turn on the hose the way you guys have it. Is there way to measure the air flow? Or to know how effective it is going to be? I am sure its working for you, but wondering how I can make sure mine is efficient once I finish routing it.

1addiction · 05-01-2010, 03:22 PM

ooo im interested in this

Jori · 05-12-2010, 09:57 AM

Cool idea at all

Elsabor67 · 05-12-2010, 03:04 PM

I definetly like simplicity. That looks very simple and effective.

Groundpilot · 04-05-2011, 11:39 AM

I didnt know OEM dust shields are removable. Did anyone try to remove them only without doing the whole duct thing. I know its not going to be nearly as effective but i would think by removing them more air will travel around rotors and they will cool down better than with dust shields that block air. What do you guys think?

Groundpilot · 04-28-2011, 04:27 PM

Well, looks like dust shields are necessary to protect weel bearings from an excessive heat

octironSmith · 05-03-2011, 07:07 AM

Quote:

Originally Posted by M3 09 AND135I 11

Well, looks like dust shields are necessary to protect weel bearings from an excessive heat

Any details into this?

dsm 135i · 05-08-2011, 04:08 AM

Does anyone know if these fit like they say?

http://store.bimmerworld.com/carbon-...tes-p1412.aspx

11-13-2009, 12:59 AM	#1
BerkTechnology Lieutenant Colonel Drives: Fast Join Date: May 2008 Location: Irvine, CA Posts: 1,566 iTrader: (1)	DIY - custom brake ducts for under $100 This is a quick DIY for those of you who want to make a real set of brake ducts. Prerequisites are: A) You have at least two full days of free time. B) You can fabricate basic things out of metal C) Welding skills D) You track your car on a regular basis. If you are a street guy then the OEM brake ducts (if you could call them that) are working fine for you. Materials needed: Silicone or nomex ducting 2.5" or 2" will work fine. scrap 20 gauge sheet metal scrap 16 gauge sheet metal scrap 2.5" or 2" steel tubing hose clamps lots of zip ties 1. Remove caliper and rotor. The rotor is held in with a large philip screw. If you didn't know that's the one shaped like a "plus" sign then stop now. 2. Remove the OEM dust shield. It's bolted in with a few bolts. 3. Remove inner splash guard. 4. Remove OEM plastic ducting completely on driver side. 5. Partially remove plastic ducting on passenger side. You'll need to keep the ducting for the OEM oil cooler in tact. We don't want to mess with that as BMW did a good job in the air ducting to that little cooler. They didn't do such a great job in sizing that cooler though. 6. Fabricate backing plates using the 16 gauge steel as your base. Drill a hole and place your inlet hose as close to the center of the rotor as possible. 7. Fabricate a new mounting plate for the air inlet at the front bumper. Use the OEM mounting tabs that held in the OEM brake ducting to hold your new plate in place. 8. Route the hose as needed to clear all of the suspension pieces. Make sure to turn the wheels from full lock both ways to make sure you don't have any binding going on. Your end result will look something like this. The Rotora 355mm BBK is optional! Have fun! PM me if you guys have any questions. Always here to help the DIY guys out!
	Tweet

11-22-2009, 11:56 AM	#2
Jettafanatic Private First Class Drives: 135i Join Date: Sep 2009 Location: Santa Barbara, CA Posts: 120 iTrader: (2)	For those with no welding skills / just plain lazy.... You can use this instead and modify / rivet it to the backing plate / intake plate (a little more expensive though) Ora cheaper / no weld ( still rivet ) way: http://www.aircraftspruce.com/catalo...uctflanges.php ( I used these on my ducts on a racing jetta I had... ) Nice job Guys! __________________ Legal Disclaimer: Anything I or anyone else says about my vehicle on this website(1addicts.com or any affiliated or nonaffiliated sites), pertaining to modifications, is only to gain acceptance from my/our peers, and does not actually represent anything actually existing on my car, and thus, cannot be held against me in any issues, i.e. warranty claims, that may arise.

01-15-2010, 10:35 AM	#3
Ruffan Member Drives: '09 135i Join Date: Sep 2008 Location: Gotham Posts: 392 iTrader: (1) Garage List 2009 135i [0.00]	Has anyone done something like the suggestion above from Jettafanatic? __________________ 2009 135i Dinan Stuff

05-12-2010, 03:04 PM	#7
Elsabor67 aiming for 450..... Drives: La Jeva ;-) Join Date: Feb 2009 Location: Stuttgart, Ge :-) Posts: 2,282 iTrader: (18) Garage List 2009 135i [5.00]	I definetly like simplicity. That looks very simple and effective. __________________ Quote from Ezeedee regarding car mods: "you're only done when you sell the car "

04-05-2011, 11:39 AM	#8
Groundpilot Lieutenant Drives: 135I DCT , e92 M3 DCT,535 I Join Date: Mar 2010 Location: long island,ny Posts: 592 iTrader: (0)	I didnt know OEM dust shields are removable. Did anyone try to remove them only without doing the whole duct thing. I know its not going to be nearly as effective but i would think by removing them more air will travel around rotors and they will cool down better than with dust shields that block air. What do you guys think? __________________ David

04-30-2010, 12:54 PM	#4
Alow First Lieutenant Drives: 09 128i Join Date: Jul 2008 Location: Kansas City, MO Posts: 367 iTrader: (1)	Berk, I'm no expert, but I have never seen the 180 degrees turn on the hose the way you guys have it. Is there way to measure the air flow? Or to know how effective it is going to be? I am sure its working for you, but wondering how I can make sure mine is efficient once I finish routing it.

05-01-2010, 03:22 PM	#5
1addiction Banned Drives: 135i Join Date: May 2010 Location: Orange County Posts: 29 iTrader: (0)	ooo im interested in this

05-12-2010, 09:57 AM	#6
Jori Private First Class Drives: 1series Join Date: May 2010 Location: europe Posts: 173 iTrader: (0)	Cool idea at all

04-28-2011, 04:27 PM	#9
Groundpilot Lieutenant Drives: 135I DCT , e92 M3 DCT,535 I Join Date: Mar 2010 Location: long island,ny Posts: 592 iTrader: (0)	Well, looks like dust shields are necessary to protect weel bearings from an excessive heat __________________ David

05-08-2011, 04:08 AM	#11
dsm 135i Private Drives: 2008 BMW 135i Join Date: Jun 2007 Location: Des Moines, IA Posts: 69 iTrader: (0) Garage List 2008 BMW 135i [0.00]	Does anyone know if these fit like they say? http://store.bimmerworld.com/carbon-...tes-p1412.aspx

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