[Eternal Vibration]

You know...when i first got this BMW i3 I was so excited for the gas savings and the low cost transportation. It really is a great thing compared to gas cars. I have had BMW M4's, infiniti G37, 240sx with an RB25...many cars and motor cycles over the years. This is my first electric car... YES...I love it. I will find it hard to go back to a gas only daily driver. This thing has a carbon fiber body, polymer body panels and is such a nice little hatch.

However... I realized all my excitement was cut short when i realized that the tire replacement cost was $1200 (on sale by the way) at BMW...And shopping online didnt help. You want new tires for this thing? $275/each Plus shipping and installation. I was like...wtf this is Liek Pilot Sport 4S money for a tire that is 275 width. How are these tiny tires so expensive! Well, the low production volume and small selection/competition for these tires makes it expensive.

What should cost $100/tire to replace costs 3x that and all that money I saved over the past 6 months in gas is gone!

Hummm...I don't like it. Is there a solution? The short answer is no. I looked almost everywhere for alternative tires/wheels and a more affordable price. NOTHING.

So I said...well I can fix this. I will buy a set of used BMW 3-series wheels, get some spacers to make them fit, and then make a set of wide fenders to keep things in check.

I bought the wheels with almost new tires on them for $600. OEM Michelin tires. i got spacers with extended lug bolts for $150 so I am in $750 with wheels,tires,and spacers so far.

We just got a new 3D printer at work. I am going to 3D Scan, Design and 3D print wide fenders for the car to match the wheels. Stay tuned for progress and updates!


BTW, this thing drives WAY better than the factory wheels and tires. Normally low-profile tires make things more harsh and less compliant. Bu there is a significant difference in difference in ride character. Its smoother, quieter, and handlers way better. the turning response is better. I was expecting everything to be worse, but its not. Its better, buy a lot! I have not even maximized the profile of the tires. Both the front and rear can go up 1 profile size to match the diameter of the factory wheels. Which would make it even softer.

F: 19x8+27 225/40/19 w/25mm spacer
R: 19x8.5+40 255/35/19 w/30mm spacer (can be 5mm lower but I wanted the track of the back to match or be wider than the front)

[airman1]

Cool. Watching your progress. How about the effect on range?

[Eternal Vibration]

I have not checked the range yet. I will update on the progress. I had issues with the 3d scanner yesterday so I might have to get a new one to accomplish what I want to.

Here are some pictures of the 3D printer. And recent parts made.

[who is this noob]

Subscribed for box flares.

[airman1]

Cool!

[Eternal Vibration]

Working on the cad model.

I might try might try two different designs. I will update when at least 1 is finished

[Eternal Vibration]

Sorry for the long delay. I was hoping to get this finished sooner.

Some progress pictures. These are design to just cover the flat part of the fender. Similar to the oem i3S fender flares but much wider.

I plan to use double sided tape to fix eh fenders on and go for a clean oem look with no rivets or visible hardware.

[1543625891ygz@gmail.com]

Hi how is your progress so far? I'm also looking forward to change to wider tire and 3d print the flares.

[Eternal Vibration]

I have a small update. Sorry for the delay.

I have spend some time refining the shape and the geometry. Also since the 3d printer is only 10x10x10" I can only print small sections at a time. So I had to divide the fender into smaller parts. Here is what it looks like in the printer.... 17hrs to print 1 fender.

[1543625891ygz@gmail.com]

Wow it's pretty nice! From my personal experience i don't think these pieces need support. I have a x1c as well and it can handle 70-80 degrees overhang with no issues.

[Eternal Vibration]

The supports are for rigidity. The parts are long and thin...there are forces in 3d printing and without supports, toward the top of the part the sections will flex and create a poor surface finish in the print. the supports keep the part from flexing as it gets taller and taller. Its not so that it can support the actual print lines.

[Erik-AA]

I am super interested in this project! When they're ready I'd be happy to buy a set or print my own. I drive a 2018 i3S, so it has the small factory flares. Is there anything I can do to help?

[Eternal Vibration]

Ok. I finally finished the first fender.

Its pretty good, but not perfect. I am going to make some minor adjustments and print a new one. But I am very happy with how OEM it looks.

I am going to extend the fender down to the black parts of the bumper and the side skirts. I don't like the black/silver/black gap.

My goal was a "super" i3s fender flare.

[1543625891ygz@gmail.com]

That's so amazing! I'm willing to pay for the stl files once you finish the final design as well!

[Used1100]

Is it possible to send me the i3 model you are using?

[1543625891ygz@gmail.com]

How is the process so far? I'm super interested. I initially want to design and print them myself, but i don't have a 3d scanner which makes things so much harder. Are you willing to share the stl file or i can pay for them. Thank you for your effort!

[Eternal Vibration]

So a quick update, I have decided to remake the fenders slightly differently. They are going to extend all the way to the ends of the original fender. I don't like the gap between the black and the silver and the black. So I am going to extend them and make them silver instead of black front and rear.

[3rigel]

Great little project. The tyre issue is a pain for all owners. I had a word with a plastic supplier who has bespoke projects made. He spoke about a template being made with the original wings and then manipulating them to give a more proud arch wing etc. Off the top of his head he said jigs would cost £1500 to £2000 a corner. After that the forms would be quite cheap in comparison.

[Erik-AA]

Great progress! I will be very happy to put sportier and less expensive tires on my i3. Thanks!

[TractionControlDelete]

Love it!!

Obviously…
https://youtube.com/shorts/3kcpAubnm...XSBR35EGZbTjzr

[TractionControlDelete]

Originally Posted by Eternal Vibration

So a quick update, I have decided to remake the fenders slightly differently. They are going to extend all the way to the ends of the original fender. I don't like the gap between the black and the silver and the black. So I am going to extend them and make them silver instead of black front and rear.

Can’t wait to see how this turns out! I’ve got some eBay over fenders that I haven’t installed yet but this would be SO much better. Really happy you’re doing this. Folks have been going this route (i8 wheels w/ spacers and over fenders):