Materials to Maintain Your ZHP IIIII Hand Protection IIIII Tools to Maintain Your ZHP
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  1. #1
    Join Date
    Jun 2011
    Location
    Redondo Beach, CA
    Posts
    1,944

    Bringing a fender rolling tool back to life and more

    At our SoCal meetup a few weekends ago, Hieu (sillieidiot) was nice enough to let us borrow his fender rolling tool. Unfortunately, as soon as I started to use it it self destructed on me. Returning a tool broken is not cool so I volunteered to fix it and while doing so it became obvious that the way it was designed and made, they simply won't survive a lot of use so I did a couple extra things to hopefully strengthen it enough to last.

    One of the problems was due to misuse. Myself and others attached it onto the car using the lug bolts. THIS SHOULD NOT BE DONE. Because it is designed to work on either 4 or 5 lug cars, two pairs of the holes at 9 and 3 o'clock are so close together that the conical shape of our lug bolts will deform the metal between the holes causing the tool to loosen itself during normal use. This then causes the whole mounting surface where it attaches to the car to bend and curl, and at least in his case, crack the welds, and the more you use it, the worse it gets. I did not take pictures before I pressed it back flat and re-welded it but here's an after pic:



    I had some extra time so I flipped it over and ground the side that mounts to the car perfectly flat. Not really necessary but it looks cool:



    This is the actual part that self destructed:



    This is the shaft that exerts all the pressure on the roller that actually rolls the fender lip. I have no idea why they designed it with just a 12mm bolt and washer attaching it. It will last a few uses but eventually the threads will give out and it will look just like this one. Re-threading that to 7/16:

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    took care of the threads but now will be slightly weaker than the original 12mm bolt. To prevent that from self destructing again I did what they should have done:

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    Milled out a larger surface area and fit a thrust bearing on it.

    Next up is the way they attached it to the tool:

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    There's two problems with this. That center part needs to rotate, which means you can't tighten the socket head screw completely, and it's never a good design to have things rotating on the threads of screws. This is the kind of thing that really annoys me as there is no cost difference between screws that are threaded all the way and those that have a shoulder:

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    Now you can tighten the screws completely and it will rotate on the shoulders instead of the threads:

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    And here's the roller assembled back together better than new and should last through plenty of uses:
    2006 CiC 6MT
    ZHP, Cold Weather, Xenon
    Sapphire Black / Black Leather / Black Cube

  2. #2
    Join Date
    Jun 2011
    Location
    Redondo Beach, CA
    Posts
    1,944
    Here's the final pic:

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    2006 CiC 6MT
    ZHP, Cold Weather, Xenon
    Sapphire Black / Black Leather / Black Cube

  3. #3
    Join Date
    Jan 1970
    Location
    Liberty Township, OH
    Posts
    37,935
    Beautiful work.

    Sent from my Samsung Galaxy S4
    Call Me Dane l 2/2004 330i ZHP l 18x8 ET45 BBS CK's wrapped with Michelin Pilot Sport AS3+ @ 245-40-18 l KW V1 Coilovers in front l KW V1 springs w/ Bilstein B8 dampeners in rear l BMW Performance Rotors l UUC StrutBarbarian l Racing Dynamics Rear Strut Bar l Jim Conforti Shark Injector l Light Birch Interior Trim l Bimmian Celly Mount l M3 Trunk Mat l l e90 Performance E-Brake & Shift Knob l M3 Tri-Stitched Boots l AL Headlight Retrofit with ZKW Lenses l CobyWheel Wrap w/M3 Stitching l LCM sw 4.5 triple blink and rear fogs l Maple Interior Trim

  4. #4
    Join Date
    Jan 1970
    Location
    Southern California
    Posts
    18,064
    +1. Nice job. Looking forward to our SoCal fender rolling day again!
    Randeaux/Rando/John/jr - '06 Cic ZHP; Southern California
    "ZHP or not, I still like you"


    ZHP Performance Package, Cold Weather Package, Leather, Jet Black/Black/BlackCube, NAV, Anthracite Black "my individual" interior trim
    ESS Stage 1 Twin Screw Supercharger, Sprint Booster, BMW Perf Intake, Magnaflow Exhaust, Dinan TB & STEP S/W, UCC Sway Bars, Apex EC-7 18x8.5 ET38
    Suspension: AST 44100 dampers, Bimmerworld front adjustable end links, Swift springs (8K front, 10K rear), Vorshlag camber plates
    Dynavin D99+, Hardwire V1 (w/V1 Connection), BSW Stage 1 Speakers, Kicker Amp/Subwoofer
    BMW Performance Strut Brace, Orion V2 Angel Eyes, No-holes License Plate, SMG Paddle Shift Mod, Besian VANOS, Gold DISA, Fan Delete, M3 Side Mirrors
    Note: Actual car no longer resembles signature picture

  5. #5
    Join Date
    Sep 2011
    Location
    San Francisco, CA
    Posts
    6,847
    Good repairing a poor design.

  6. #6
    Join Date
    Aug 2011
    Location
    San Diego, CA
    Posts
    2,785
    It's awesome you were able to do this! Now it can get back to rollin'.

  7. #7
    Nice work.

  8. #8
    Join Date
    Jun 2011
    Location
    VA/DC
    Posts
    14,445
    Nice work. Did the BEast coast one get repaired after the reunion or perhaps its still usable.

  9. #9
    Join Date
    Jan 1970
    Location
    Liberty Township, OH
    Posts
    37,935
    Quote Originally Posted by ELCID86 View Post
    Nice work. Did the BEast coast one get repaired after the reunion or perhaps its still usable.
    Still works fine.

    Sent from my Samsung Galaxy S4
    Call Me Dane l 2/2004 330i ZHP l 18x8 ET45 BBS CK's wrapped with Michelin Pilot Sport AS3+ @ 245-40-18 l KW V1 Coilovers in front l KW V1 springs w/ Bilstein B8 dampeners in rear l BMW Performance Rotors l UUC StrutBarbarian l Racing Dynamics Rear Strut Bar l Jim Conforti Shark Injector l Light Birch Interior Trim l Bimmian Celly Mount l M3 Trunk Mat l l e90 Performance E-Brake & Shift Knob l M3 Tri-Stitched Boots l AL Headlight Retrofit with ZKW Lenses l CobyWheel Wrap w/M3 Stitching l LCM sw 4.5 triple blink and rear fogs l Maple Interior Trim

  10. #10
    Join Date
    Aug 2011
    Location
    Las Vegas, NV
    Posts
    5,877
    Quote Originally Posted by johnrando View Post
    +1. Nice job. Looking forward to our SoCal fender rolling day again!
    No doubt! Mighty fine job William! After seeing this I feel Very comfortable with you working on my Sprint Booster Mod!
    BAV Stage 1 - BlueBus - UltraGauge - V1 - Orion V4's - ARC-8's - Brembo 996
    TTFS Engine/SMG Tune/CSL 255 - SGT Headers/Sect 1/SCZA - Evolve Eventuri
    VIS XTS CF Hood - CF Lip/Console/Diffuser - OE CSL Trunk - BWS 500S 9k/11k

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