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DIY Chassis Braces
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Thread: DIY Chassis Braces

  1. #1
    Senior Member Shailer Andrew's Avatar
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    DIY Chassis Braces

    Hey all,

    I'll be honest I don't have any pictures of the process because I made these very last minute in my dad's garage before leaving for a Co-op, but I wanted to explain the simplicity and possibility of doing this mod yourself. Here are the finished products, I'll let you decide if you want to read further.


    At first, upon seeing the factory braces and the RRM braces which both have a curve, I was concerned that there would be clearance issues with using a straight spreader tube. I did more searching and found the DNA chassis braces, which are also straight like mine. I believe there is a possibility of the spreader bar contacting the transmission, but this is easily avoided and would be apparent before welding.

    Here are the basic steps I used to make these. I'm writing this based off of my memory so I would have to double check some of my dimensions if anyone is really interested.

    1. Measure OD of socket for mounting bolts (15mm?) to determine minimum ID of tube used for mounting cups.

    2. Cut 4 lengths of that size tube in lengths of roughly 1 1/4". I used a pipe cutter to ensure square cuts.

    3. Use hole saw of similar size to ID of mounting cup tubing to make 4 pucks out of 1/4" plate.

    4. Place the pucks on top of the mounting cup tubing and fillet weld around the circumference. Grind the weld even with the puck so it can mount flush to the flat mounting points on the vehicle.

    5. Use a larger drill bit to open mounting holes in pucks in order to allow for the mounting bolts to fit through. I believe I used 3/4"

    6. Once all of of the mounting cups are made, unbolt your existing chassis braces and bolt the cups to the vehicle. Assuming you have sized the ID with small clearance to the socket then this should act as enough of a centering method when you mount them, but regardless it is not crucial.

    7. Take approximate measurement of distance between upper and lower cups. These cups do not necessarily mount on the same plane so be sure to leave some excess when cutting the spreader tube. The length of this tube will vary based on the OD of the mounting cups but it will be less than 12". I used 3/4" OD.

    8. This step is basically trial and error. Using a grinder with a flapper wheel or a die grinder with a carbide burr begin to notch the spreader tube appropriately so that it meets flush with the upper and lower cups. The left and right sides are different so don't try to duplicate the first one you complete.

    9. It might help to have another person to help with this but it can be done alone. We used a MIG welder and tacked the spreader tube to the mounting cups while installed on the vehicle in order to maintain orientation.

    10. Remove the braces from the vehicle and finish weld around the spreader tube. You might also want to make some sort of punch marking to indicate the top side of the brace along with a mark to distinguish left to right.

    11. Paint to your liking and install.

    12. Hammer down.

    Other than being aware of avoiding contact to the transimission, the only other place that contact could be possible is on the upper mounting cup. I'm on the factory 17s at stock front ride height with no wheel spacers and there was no contact at full steering lock. This may not be the case with wider wheels or different offset, or if you make the mounting cups too tall.

    I hope this was in some way helpful and if you have any questions or are interested in my exact dimensions then let me know. The improvement in responsiveness in this mod is absolutely unbelievable. I did this mod while running snow tires (which I still have installed) and I'm still blown away by how this thing handles. I can't imagine how it will feel on a good set of rubber. Other than the handling, the car feels much more solid. The car's reaction to road imperfections is much more unified. No longer does it feel like the body and damper are behaving one way while the subframe reacts in its own vibrating manner.

    I did not perform any sort of calculations to determine what the wall thickness these parts needed to be in order to hold up, but based on good judgement/ what I had laying around, it produced a great result. Anything made of tube is going to outperform the stamped pieces. Once you remove them you'll understand my point. Enjoy saving huge $$.
    Last edited by Shailer Andrew; 02-12-2017 at 12:23 PM.

  2. The Following User Says Thank You to Shailer Andrew For This Useful Post:

    markjar (05-05-2019)

  3. #2
    Super Moderator Tweak's Avatar
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    Nicely done and sticky worthy.

    Thanks for sharing.

  4. #3

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    Glad I saw this thread, I was thinking of doing the exact same thing. I built my own Roll Bar too and the main hoop mounts are very similar, just larger pipe.
    I will definitely be building my own chassis braces now. I believe I can make the bottom one too.

    2013 500 Sport - Espresso Brown
    2017 500c Abarth Cabrio - Rosso Red
    Abarth mods:
    XXR 527 Chromium Black Wheels
    4 Point Roll Bar
    Maxton Design Front Splitter
    RRM Ultimate BASIC ECM
    MPx Axle Back Exhaust
    Bosch 4C Coils
    NGK Iridium Plugs
    MPx Blow Off Plate
    GFB+ Diverter
    EC Red Intake & Ram Air Pipe.
    500 Madness Red/CF Front Brace
    Speedlab Hood Strut Kit
    Speedlab 25mm Front Sway Bar
    CFP 25mm Rear Torsion Bar
    DIY Chassis Braces
    KYB Rear Shocks
    Many, Many more....

  5. #4

    Join Date
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    Have you noticed a difference with these on?

    2013 500 Sport - Espresso Brown
    2017 500c Abarth Cabrio - Rosso Red
    Abarth mods:
    XXR 527 Chromium Black Wheels
    4 Point Roll Bar
    Maxton Design Front Splitter
    RRM Ultimate BASIC ECM
    MPx Axle Back Exhaust
    Bosch 4C Coils
    NGK Iridium Plugs
    MPx Blow Off Plate
    GFB+ Diverter
    EC Red Intake & Ram Air Pipe.
    500 Madness Red/CF Front Brace
    Speedlab Hood Strut Kit
    Speedlab 25mm Front Sway Bar
    CFP 25mm Rear Torsion Bar
    DIY Chassis Braces
    KYB Rear Shocks
    Many, Many more....

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