DSE Carbon Fiber Bracing

[SSGNRDZ_28]

I’ve been working for several months on replacing some of the steel bracing in the engine bay area with bracing made from carbon fiber and aluminum. The goal of the bracing is to maintain strength/stifness, reduce weight, be bolt-on, and improve upon the look and long term resistance to corrosion from the OEM parts.

I’m currently working on 3 braces, those made from 1.5” tubular bracing, that are located in front of the engine (airbox mount) and on the sides connected to the x brace. The total weight savings will be over 10 lbs for the set. Front brace is over 2 lbs saved, side braces over 4lbs each. Of course this weight is higher up in the front of the car so somewhat more significant than some other locations.

As the diameter of the carbon fiber keeps the 1.5” diameter, the bracing is compatible with DSE catch cans along with most anything else that might clamp onto or be mounted near the existing brace.

The carbon fiber being used has been constructed to be equivalent in stiffness to steel and is being bonded to the aluminum with high strength epoxy. All materials can survive at the elevated temperatures of the engine bay and I have tested this through the prototyping phase.

The carbon fiber is cleared before assembly, the aluminum is hard anodized and hardware (as required) is either stainless or high strength zinc coated steel depending on the requirement.

Anticipated prices are $775 for the front brace and $955 for the side braces.

I’m ready to head into production on the front brace and will soon have updates on the side bracing. If interested let me know so my quantities are sufficient for the first run.

Thanks
Doug

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High temperature load testing
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[Bill Pemberton]

Day-yammmm, you always make such cool stuff Santa Doug!!!! Super impressive and not sure why I should be surprised , just your typical thoroughness for the Viper faithful!

[ViperGeorge]

How hard is the install?

[stradman]

Hi Doug. Great work buddy! Just awesome. I presume the side braces are sold as pair right?

[13COBRA]

Amazing work as always Doug.

[DADS ACR]

Doug, they look amazing so count me in for both. :-)

I think Alex is getting the coolers and drive shaft this week so thank you!

[dewilmoth]

Way cool product idea.

Has there been any consideration for Carbon sway bars like the GT2RS WP? I’d assume the OE bars are way heavy.

[stradman]

Way cool product idea.

Has there been any consideration for Carbon sway bars like the GT2RS WP? I’d assume the OE bars are way heavy.

Good idea. And make em adjustable too! Seems like QA1 have started doing this..

[13COBRA]

Great idea on the sway bars!

[512BB]

Gorgeous stuff!

[SSGNRDZ_28]

Day-yammmm, you always make such cool stuff Santa Doug!!!! Super impressive and not sure why I should be surprised , just your typical thoroughness for the Viper faithful!

Thanks Bill!

How hard is the install?

This front brace is 4 bolts, just need to remove the airbox for access. The side ones will require X brace removal and cowl cover removal.

Hi Doug. Great work buddy! Just awesome. I presume the side braces are sold as pair right?

Thanks yes the side should be a pair but the price above is per side. 10 pieces go into the side assembly (not including hardware) as nothing is a straight angle on these cars the assembly is fairly complex (especially for the rear x brace /hood latch mount).

Amazing work as always Doug.

Thanks!

Doug, they look amazing so count me in for both. :-)

I think Alex is getting the coolers and drive shaft this week so thank you!

Thank you, he should have everything soon; looking forward to your feedback on the driveshaft as well.

Way cool product idea.

Has there been any consideration for Carbon sway bars like the GT2RS WP? I’d assume the OE bars are way heavy.

Thank you, I’ve been working on this some, actually have a carbon fiber piece but haven’t had time to do anything further just yet. With getting the rates correct there is a little more involved in these to get them right.

[Arizona Vipers]

Count me in Doug! Another 10 lbs off the nose!

[SSGNRDZ_28]

Test fit of the driver side brace went well, this one is over 4 lbs ligter per side than the OEM piece. Installation is fairly easy, maybe a total of 1-2 hours for all 3 braces.

Doug

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[ACRSNK]

Very cool!

[stradman]

Real nice Doug! Can I ask, is it possible to do the alloy bits in black? I most certainly will be up for these braces although just have a couple of other things I need to attend to and am looking at the moment by way of priority ie. new muffler and new brakes

[SSGNRDZ_28]

Real nice Doug! Can I ask, is it possible to do the alloy bits in black? I most certainly will be up for these braces although just have a couple of other things I need to attend to and am looking at the moment by way of priority ie. new muffler and new brakes

Yes this is just a test fit, all aluminum parts will be black.

Thanks
Doug

[ViperGeorge]

Doug, did you ever think about making your airbox heat shield out of carbon fiber? Would that insulate as well? It would be lighter.

[Exhlr8n]

Another Phenomenal product. Another one to add to the wish list!

[IHOP]

Ok Doug, since no one else has volunteered I will. If you for any reason would like a remote 2nd test mule you can send me whatever amazing product you are making and we can test fit and almost daily real world on road test them. Hahaaha! Awesome work as usual Doug!

[stradman]

Can I ask please Doug. Where the X Brace bolts onto the bracket which in turn is bolted onto the side CF brace. How is that bracked secured on the CF side brace? is it just clamped and bolted on? I ask as I would be worried of some possible rotational movement on that bracket due to the forces from the X brace flexing and translating the force to the bracket. This would be undesirable. I say this as the clamps/brackets that hold the catch cans are of a similar design and those can rotate(albeit those are not subject to any forces). Could you please clarify? Cheers
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[SSGNRDZ_28]

Shown here it is just sitting in place but there are two set screws on each piece as secondary measures but all of the aluminum pieces are also bonded to the carbon with high strength/temp epoxy.


Edit - the catch cans should have no movement, you could probably break the bracket before it rotates at least on my car and the others I've done - might be something to look into if yours are moving/rotating.

Can I ask please Doug. Where the X Brace bolts onto the bracket which in turn is bolted onto the side CF brace. How is that bracked secured on the CF side brace? is it just clamped and bolted on? I ask as I would be worried of some possible rotational movement on that bracket due to the forces from the X brace flexing and translating the force to the bracket. This would be undesirable. I say this as the clamps/brackets that hold the catch cans are of a similar design and those can rotate(albeit those are not subject to any forces). Could you please clarify? Cheers

[Voice of Reason]

Some quick math:

OEM carbon fiber X brace - $3k - saves 2 lbs 7 oz

Doug’s 3 carbon fiber bracing pieces - $2,685 - saves 10+ lbs


Anyone looking to save weight this is awesome. And when combined with the lightweight battery in the trunk it even helps keep f/r weight balance in check.

[stradman]

Shown here it is just sitting in place but there are two set screws on each piece as secondary measures but all of the aluminum pieces are also bonded to the carbon with high strength/temp epoxy.

Cheers Doug. So the screws/bolts go through the Carbon brace and on to the other side then to further avoid any rotation?

[SSGNRDZ_28]

The screws are set screws that clamp top and bottom but do not go through the carbon, a total of 4 of these for the assembly. When the X brace support is assembled as pictured (without set screws or epoxy) there is no risk of rotation or even sliding along the tube due to the tight clearance to the tube and the way it all goes together. The next step will be injecting epoxy into the set screw holes, there is a machined channel to allow this to flow / fill inside of the pieces that surround the tube. Remember adhesive is strong enough to bond a driveshaft yoke to a carbon tube. Lastly the 4 set screws are installed to finish it off. With all of this and the way the force is applied through the x brace I’m not at all worried about movement of this piece

[Arizona Vipers]

Some quick math:

OEM carbon fiber X brace - $3k - saves 2 lbs 7 oz

Doug’s 3 carbon fiber bracing pieces - $2,685 - saves 10+ lbs


Anyone looking to save weight this is awesome. And when combined with the lightweight battery in the trunk it even helps keep f/r weight balance in check.

You want weight off the front more than anything, which is hard to do on this car. When Dodge listed this car as 51/49 this wasn't true, stock my 2013 was 53/47 and my acr was worse, 54/46. I think they take that measurement with full fluids, meaning with 101 lbs of gas in the back