DDMWorks Pro-Beam

[Randy@DDMWorks]

Life and Death of a Brace

With the Kappa community starting to have options in the power development of our unique platform, DDMWorks has been in development of new suspension and other components. Drawing for our extensive work with other roadster platforms, we have developed a rear structural cross member brace for your Kappa.
Beginning in the early fall of 2007, we began testing prototypes for a stiffening brace on our test Solstice. The objective was to improve on some shortcoming built into our beloved car due to the nature of production vehicles. We began with some very simple and straight forward concepts. However, our test mule proved to be quite a fighter. Feeling all good about a brace design, we merrily bolted up several prototypes and went blasting down the back roads. At least 3 different design concepts met their untimely demise this way. The problem? Our primary test vehicle is lowered and has an aftermarket exhaust. Most of the concepts that we modeled would work perfectly on a stock Kappa, but being lowered and having an aftermarket exhaust killed several designs we had spent days modeling in the computer. Below the photos show several design that, obviously, did not make the final cut.






We continued our quest with what we called the "X-brace". Very functional and VERY cool looking from the rear. But the lowered vehicle and Center exit exhaust setups still proved to be a problem.



Then we engaged a few GM Performance Racing engineers about the problems and what they had discovered were the weakness of the Kappa. From our track brothers in SSB & T2 SCCA racing, we discovered that it's not so much the two lower rear control arm mounts thats the problem. The engineers at GM found the cross member that holds the back of the differential in place is flexing. Although this looks to be very beefy, it is actually very thin metal filled with foam. Due to this flex, all ZOK's use a HD version of this piece. We we're able to inspect the changes they made at the factory, and tailored out new brace like-wise. To do like GM, you would have to weld additional steel in place, not for the average shade tree mechanic.




The DDMWorks Rear Pro-Beam is engineered to bring your light-duty stock cross member up to the par with the 2006 & 2007 SCCA winning Kappas. It has been tested on vehicles lowered as much as 2" with low profile tires. It survived over 10,000 miles of abuse on roads that most of you would never take you rides. Exhaust fitment has been verified with Stock, Magnaflow, SOLO Center, GM Performance and DDMWorks exhaust systems. This is the first brace to tie and link together the diff. cross member to the suspension mounting components. It is made from high quality STEEL and is seam welded. The brace is E-coated black for corrosion protection. Installation is accomplished with simple hand tools and an electric drill.


The DMMWorks Rear Pro-Beam will be available at an introductory price of $159 and will come with Stainless Steel hardware and complete instructions. They available for Pre-Order now and should be in stock and ready to ship on March 14th

[Jaysmith2000]

Hi Randy!

Great to see the evolution of this design. It's very encouraging that you worked with GM Engineers on this. Just one question, that I'm sure you're going to get from a lot of us, will it work with the RPI GT Exhaust? I believe the design will allow it to work, but not sure. Any idea?

Thanks!

[Randy@DDMWorks]

Originally Posted by Jaysmith2000

Hi Randy!

Great to see the evolution of this design. It's very encouraging that you worked with GM Engineers on this. Just one question, that I'm sure you're going to get from a lot of us, will it work with the RPI GT Exhaust? I believe the design will allow it to work, but not sure. Any idea?

Thanks!

Thats an exhaust we have not seen yet...If you can send us pictures, we'll look at it for you. It should fit most anything. We will be glad to work with you on it if you want to try it.

[Jaysmith2000]

Originally Posted by Randy@DDMWorks

Thats an exhaust we have not seen yet...If you can send us pictures, we'll look at it for you. It should fit most anything. We will be glad to work with you on it if you want to try it.

Thanks Randy. Here is a thread with some great pics of the underside with the GT exhaust (albeit a bit dirty.... ). I can send you more pics of mine if you need certain angles. It is the 4th post down from the top.

reBAR Installed

[clif]

Originally Posted by Randy@DDMWorks

Thats an exhaust we have not seen yet...If you can send us pictures, we'll look at it for you. It should fit most anything. We will be glad to work with you on it if you want to try it.

Well, after trying the competing product and finding fitment issues, I am willing to be a test mule. I am sending an email to Ivy to be on the pre order list as after looking at the design and having JUST been under my baby, I think you might fit!

Clif

[DeepBlueGXP]

What guage metal are you using, does the three holes have to be drilled into the support bracket. E-coated is that like powder coating. Sounds like your design supports more exhausts than the other one on the forum.

[Randy@DDMWorks]

Originally Posted by DeepBlueGXP

What guage metal are you using, does the three holes have to be drilled into the support bracket. E-coated is that like powder coating. Sounds like your design supports more exhausts than the other one on the forum.

The DDMWorks Pro-Beam is made from .100" Steel. The"E-Coat" is a coating used by OEMs It's a little more robust than powdercoating...If you look under the hoods of GM, BMW, Honda's, most of you black bracketry is E-Coated...It has a semi-matte finish.

One of the holes (center) already exist...you just have to drill through the foam. Basically drill the center thru....Bolt it up, drill the two side holes...garranteed to fit then...

[Celt03]

Will this work on a dual exhaust - (stock &/or Magnaflow) ?

[Randy@DDMWorks]

Originally Posted by Celt03

Will this work on a dual exhaust - (stock &/or Magnaflow) ?

Yes, the stock and Magnaflow should fit with no issues

[Celt03]

Originally Posted by Randy@DDMWorks

Yes, the stock and Magnaflow should fit with no issues

Cool !!

[JohnD]

Originally Posted by Jaysmith2000

Thanks Randy. Here is a thread with some great pics of the underside with the GT exhaust (albeit a bit dirty.... ). I can send you more pics of mine if you need certain angles. It is the 4th post down from the top.

reBAR Installed

Be careful. I think that post clearly states that this is NOT the RPI exhaust, but something that HOMER and a buddy rigged up as a one-off.

[kwayne]

If you put the ZOK brace on, would there be any benefit to adding the additional bracing (whether it be yours or someone else's)?
Thanks

[Randy@DDMWorks]

Originally Posted by kwayne

If you put the ZOK brace on, would there be any benefit to adding the additional bracing (whether it be yours or someone else's)?
Thanks

It would serve to stiffen up the rear even more. Would you see as much of a change as a non-Z0k..Probably not. but good question. Unfortunatley, we don't have a Z0K to play with

[Sunny Ragtop]

Should the UPGRADED exhaust be put on BEFORE installing the Pro-Beam. Would it have to be removed to install a new Borla Single Exhaust system for my 2.4?

[Randy@DDMWorks]

Originally Posted by Sunny Ragtop

Should the UPGRADED exhaust be put on BEFORE installing the Pro-Beam. Would it have to be removed to install a new Borla Single Exhaust system for my 2.4?

Shouldn't matter. I have installed and removed the Pro-Beam with the exhaust on. Once it's on, it will be above the exhaust, so you shouldn't have to ever remove the brace to do any exhaust work.

[rhian]

Can we see some additional pics of how it get's installed. I assume that from your post holes need to be drilled where as the Kappasphere ReBar is a bolt on installation. How does your bracket compare to theirs? What sets your apart without getting into a war of words against competition.

[Randy@DDMWorks]

Originally Posted by rhian

Can we see some additional pics of how it get's installed. I assume that from your post holes need to be drilled where as the Kappasphere ReBar is a bolt on installation. How does your bracket compare to theirs? What sets your apart without getting into a war of words against competition.

We are working on getting some more pictures, I will post them when I have them. The installation use the same 8 holes that the other product uses, plus and additional 3 holes that are drilled into the Main Black Differential Crossmember. It is really easy to drill as the big black crossmember is really just super thin metal tubing with foam filling. One hole is actually already there, just not drilled all the way through. A simple cordless drill can perform the task in about 5 min.

The only thing I will say in reference to the other product, is that I have not seen one in person, and it does not tie into the diff. Cross member, which we believe is the weak spot in the system after consulting GM Performance people last year.

[Randy@DDMWorks]

Just wanted to let you know that the Pre-Order page is up and available on DDMWorks



Sky pre-order page:
DDMWorks

[rhian]

Thanks for the reply

[SKY Spy]

Originally Posted by Randy@DDMWorks

We are working on getting some more pictures, I will post them when I have them. The installation use the same 8 holes that the other product uses, plus and additional 3 holes that are drilled into the Main Black Differential Crossmember. It is really easy to drill as the big black crossmember is really just super thin metal tubing with foam filling. One hole is actually already there, just not drilled all the way through. A simple cordless drill can perform the task in about 5 min.

The only thing I will say in reference to the other product, is that I have not seen one in person, and it does not tie into the diff. Cross member, which we believe is the weak spot in the system after consulting GM Performance people last year.

Randy,

Since you say the metal that you have to drill to is very thin and not much support, how is the bolts threaded into this "weak" metal are going to "hold-on" to that metal without pulling out by themselves? If I understand you correctly this bar is different from the other because it "ties-in" into the differential mount cross member and if this cross member is not very tough, how is tying your bar to this going to help strengthen it if it can not stay bolted in...?

I do reialize the other 8 bolts to the lower arms keep it in place but I'm assuming that in extreme cases the 3 bolts threaded into the center support will get to do some work by keeping the PRO-Beam securely fastened to the cross member...

Not trying to question you, just trying to get some clarification...

Thanks for your time...

BA...