My proposal for a Generation III mid-chassis "stiffening brace"center"box beam.

The rails onto which the "box beam" will mount is at least 1-1/2 inches higher than the bottom of the muffler behind it. So, the bottom of the one inch box beam will still be higher than any other low ground clearance component like the lower "A" arms and the muffler.

There is no need to worrw about ground clearance of the "box beam" cross brace.

 

Those are the dimensions. I will be using an FAA classified aircraft 6061-T6 box section extrusion tracable back to the producer as far as its performance standards.

 

UPDATE; "Box Beam" mid-chassis btace for Gen III and Prius "v"

I received the tubing on Monday.

The design has been finalized. A larger clearance cut had to be milled on the ends due to the switch from 1-1/2 invh thick to thinner 1 inch tubing.

The tubing is better that I expected. The 6061-T6 tubing that I ordered is already 20-30% stronger than the architectual tubing sold on the mass market. I was pleasantly surprised that it is true "structual tubing" in that it has radius corners, instead of sharp corners which would be more likely to crack under stress.

I have over 10 units at the moment. They have been individually laid out and marked and checked for drilling. Each one will be rechecked to make sure the holes are in the correct place, many many times. They will be completed Staturday evening and will be ready for shipping on Monday.

For all of those who have PM'd me, I will be contacting you on Sunday with the details on payment and shipment. The final price is $63 delivered by Priority Mail (US only).

Again, I appreciate the interest of all.


Rude person's

 

No, longer bolts are not needed. It is made with adequate clearance to mount with the original OEM bolts and will allow you to use a standard socket and torque wrench.

Hope this helps.

 

After having made a sizeable lot of these and mounting one of these on my own vehicle, I cannot see how you got a socket over the bolt head and how you were able to torque the brace in place properly. You must have used a 14mm box wrench or a ring spanner.

 

Yes, I found that out, too. I tried several different sockets on the bolts to check clearance. Some "thin" sockets have the necessary clearance. The 12 pointers are thinner than the 6 pointers.

Any NEW ones made will have "plenty" of clearance for ANY socket. Thanks for the advisement.

 

I spent a lot of extra time and used my "old fashioned" labor intensive experience from the aerospace fabrication industry. I "skeletonized" with lightening holes to reduce the weight down to 1 lb 6 oz, which is within a fraction of an ounce of the thin flexible OEM steel brace.

 

What really counts is that yours works just as well.:cheer2:

 

Thanks for your experience and feedback. On the basis of your experience, the Version 3 has been modified with a new hole pattern that still preserves the "close fit" much better than the OEM brace. Extra clearance has been machined to and added, so that any "socket" will fit to install this brace.

Rude person's

 

Since I will be no longer making these, I have consulted with several "commercial" producers and independent shops on securing the rights to making these for sale. While each on mine have been "hand made" and on my manual machines, theirs might include annodizing and custom cutouts, but they will definetly be sold at a higher price, given thst they will be produced to sell for a profit.