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 are available for Pre-Order now and should be in stock and ready to ship on March 14th
__________________ Randy Carter - Product Manager www.DDMWorks.com
06 Classic Cool: DDMp62 supercharger #0.5b
Last edited by Randy@ddmworks : 03-04-2008 at 08:23 PM.
I like it. 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.
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 are available for Pre-Order now and should be in stock and ready to ship on March 14th
Hi
is it hollow underneath? can you post more pictures of it in different angles installed?
and
how do you compare it to the one Kappasphere offers.
__________________
Lil chromies
stubby antenna
Hahns Hi flow cat
Hahns stage II turbo
Synchronic Blow Off-Valve
RK Sports body kit
kappasphere rear valence
Solo Performance mach exhausts
konig hot swap wheels
BF Goodrich TA tires
DDM Pro Beam
I like it. 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.
I cross posted with the Sky 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...
__________________ Randy Carter - Product Manager www.DDMWorks.com
06 Classic Cool: DDMp62 supercharger #0.5b
Hi
is it hollow underneath? can you post more pictures of it in different angles installed?
and
how do you compare it to the one Kappasphere offers.
It is a Channel design, so yes it is "hollow" underneath...solid would be too much weight
I do not know, nor have I seen the other product in person. And I really do not want to comment on another vendors product. We feel the DDMWorks Pro-Beam is a superior product due to months and thosands of miles of testing.
__________________ Randy Carter - Product Manager www.DDMWorks.com
06 Classic Cool: DDMp62 supercharger #0.5b
Your first post says it is seam welded but the sides look as if they are riveted/bolted facing forward, is that a change last photo?
Most of the brace is formed from one piece, two of the angle sections are welded...The "legs" or uprights are bolted using stainless steel hardware...this is to give you some adjustability for production variances and fitment issues as well as ease of installation.
__________________ Randy Carter - Product Manager www.DDMWorks.com
06 Classic Cool: DDMp62 supercharger #0.5b
This is the one I am going to order. I believe this is far superior to the other one that is on the market. Should provide better stiffness back there.
This brace and the differential bushing should help me handle the extra ponies. 
