We wanted to dive into the design and manufacturing of our fog light ducts and backing plates for the ND brake cooling kit. They are a unique and neat part with an interesting design and impressive manufacturing process.
We start with a scan of the rear side of the front bumper with the fog light removed. We also scanned the knuckle for the backing plate and duct design. With this data, we can design the duct and backing plates!
To keep costs down on the backing plate, we opted for a stainless backing plate with a specifically designed carbon duct to aim airflow into the center of the rotor.
On the fog light duct side, the only option we saw for a nice unit given
The backing plate is produced out of stainless sheet which is the same thickness as the OEM backing plate. These backing plates are cut from a CNC laser. The ducts are produced from
The fog light ducts are also produced from
After producing both plugs, we were able to produce the molds from these units. The molds for each duct consists of (4) pieces per side to properly produce the ducts from carbon fiber.
Using the molds, we are able to produce a duct. The mounting locations are twice as thick as the duct body to increase rigidity for the mounting locations.
The ducts are produced with pre-preg carbon, which offers superior strength, weight, uniformity, repeatability, and cosmetics when compared to
After curing, these units are removed from the mold and polished to a shine.
A lot of work goes into producing ducts like these from scratch. It was a very fun and exciting project that pushed our abilities! If you have any questions, please don't hesitate to send us an e-mail. The full kit is located here for purchase and through our various vendors: https://www.verus-engineering.com/product-page/nd-mx5-miata-brake-cooling-kit