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      03-25-2018, 01:48 PM   #5
fe1rx
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Drives: 135i, 328i, Cayman S
Join Date: Jan 2008
Location: Canada

iTrader: (3)

The roll bar regs require a bolt-in cage to have backing plates at the floor mounts, so I looked for a suitable mounting area that would require minimal reforming. The soundproofing came off easily with a heat gun and scraper, then a bit of thinners to clean up the residue.
Name:  11 Floor Original.JPG
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Mounting point - note depressed area

Rather than work around the depressed area, I reformed it with a hammer and dolly.
Name:  12 Floor Reformed.JPG
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Mounting point - reformed flat

To allow the mounting plate to sit flat, I also removed the seam sealant.
Name:  13 Floor Drilled.JPG
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Mounting point - drilled

The RH backing plate includes a hole for the stud used to secure the underbody cladding. Mounting screws are aviation grade countersunk 5/16" machine screws. The 100° countersunk head conveniently avoids countersinking to a knife-edge condition in the 3/16" backing plate.
Name:  14 Backing Plate RH.JPG
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RH Backing Plate Installed

Th LH backing plate has an additional conflict with the brake and fuel plumbing.
Name:  15 Plumbing Conflict.JPG
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An additional clearance hole is needed for the stud securing the tubing braket.
Name:  16 Backing Plate LH.JPG
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Plain nuts were used for fitting purposes, but self-locking nuts will be used on final installation.
Name:  17 Backing Plate Top View.JPG
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Measuring for the carpet cutouts is a challenge. The cutouts were made with some sharpened steel tube. The vertical slit in the carpet allows the carpet to be installed around the hoop tube.
Name:  18 Carpet Cutout 1.JPG
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The result is quite neat. The carpet foam backing is quite thick, so it is necessary to mount the main hoop about an inch forward of the bulkhead if you want to do this.
Name:  19 Carpet Cutout 2.JPG
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The rear stays pick up an existing 12 mm bolt.
Name:  20 Rear Stay Connection.JPG
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In place, minus one of the stays. The hole in the front of the main hoop is a required inspection hole to permit confirming the tube wall thickness.
Name:  21 Trial Fit Less Stay.JPG
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Next stop, powdercoating.
Appreciate 4