Strutbar engine compartment broken

[BMW_User]

Yesterday I was driving on the motorway and I started hearing a creaking noise coming from the front.
At the beginning, I thought about anything related to the dashboard, centre console, top, then I opened the bonnet and I think I found the culprit.

There are 2 metal rods attached from the centre of the engine compartment reaching the sides above the front suspensions.
This picture shows the rod and the damage.
If I move it, I can hear some sort of noise resembling what I hear when I drive.

Apparently, the rod is welded to the metal body and I am not sure how to fix this.
Should it be welded again where it broke?
I'm currently abroad, and I'll have to drive hundreds of miles to get home.
It doesn't look like something that can be dangerous if left like this, but maybe I should put something in between the metal parts so to remove the noise while driving.

Any comments or suggestions?

Thanks.

 

[GuidoK]

This is a common thing to break, BMW has a repair guide for this, which basically says to weld the redesigned bracket from the facelift cars in that spot.

Regarding the driving: BMW says in their workshop manual that driving without the strutbars is not permitted.
Is the bracket still attached at the other spotwelds or is it completely flapping?
If it's still attached, I'd just drive home, but calmly, and preferably on smooth roads, and take special care at speedbumps and ramps like on the ferry or channel tunnel.
Because this is a common fail, there must be loads of people discovering this flaw/break after having done many many miles.
(who knows you'll still have that creak when this is fixed :lol: )

Maybe a local shop can carefully weld that top lip where the break is back together (mig welding with short burts; electrode welding is way to coarse for that).
I doubt a dealer has that part in stock (and having it done there is probably $$$), and the full repair also means some painting has to be done, maybe also behind the wheel arch liner.
But I'd rather have that done at home where you have your own mechanic/garage that you trust etc.

 

[BMW_User]

Thanks GuidoK for your reply.

Yes, the strutbar is still attached although moving, so I'm not sure how and where it is attached.
Certainly, it's not completely flapping and that's why I could hear the noise. Basically the strutbar keeps moving against the suspension cap and that's where the noise is coming from.
The other side of the strutbar also has a bolt obviously and this might be enough to keep it steady.
Now that I see the way it's been welded, would it be a good option to replace the strutbar together with the suspension cap or whatever is the name?

I could also have this done here in a local BMW Dealer / repair shop.
I don't think it'd take too long to do the job so that I could happily drive home?

 

[BMW_User]

When you write "BMW has a repair guide for this, which basically says to weld the redesigned bracket from the facelift cars in that spot."
Do you mean that the complete replair would include adding a new bracket of some sort?
Mine is the E85 facelift.

 

[GuidoK]

Now that I see the way it's been welded, would it be a good option to replace the strutbar together with the suspension cap or whatever is the name?

I guess you mean a strutbar?
You need to have the connection from your suspension domes to the bulkhead. A normal strutbar only goes from dome to dome (left to right), so that doesnt repairs this problem.
However there is 1 strutbar that is made in a complete triangle that takes over the function of the 2 struts coming from the bulkhead (and it is very stiff).
I have that one on my car (it's from Ultra racing):


But this one is not without it's quirks.
If you have an alarm, the strutbar will occupy the place where the bonnetswitch sits. I had to make a custom bracket and relocate the that swith to another place, which is a finnecky process to get it just right (and decently looking)

I could also have this done here in a local BMW Dealer / repair shop.
I don't think it'd take too long to do the job so that I could happily drive home?

Sure, that's up to you. But the dealer has to have that facelift bracket (and for a z4 I doubt they have it in stock or in fast delivery; parts from Münich sometimes take 2 weeks)

 

[GuidoK]

When you write "BMW has a repair guide for this, which basically says to weld the redesigned bracket from the facelift cars in that spot."
Do you mean that the complete replair would include adding a new bracket of some sort?
Mine is the E85 facelift.

Yes, the repair says to weld in a newly designed bracket. I see in the parts catalog that it has been made since feb. 2007, so there are indeed facelifts that still have the old bracket.
The new bracket has partnumber 41007193040
Partnumber 6 in the following diagram:
http://bmwfans.info/parts-catalog/E85/Europe/Z4_3.0si-N52/2007/browse/bodywork/front_body_bracket_right/

It's different from the old bracket, where the new redesigned bracket has differnt shape and relies on a bolt holding the brace instead of a tap end coming from the bracket and a nut securing the brace:
(the part itself is cheap, probably around 10quid)

partnumber 41007193040:




As welding is involved, I guess it's important to also paint the other side of the spot where it was welded to insure rust protection in the future at that spot.

 

[BMW_User]

Considering the picture you've shared, and looking at the way the original strutbars have been built, we can safely say the original solution lend itself to breaking.
Not sure how they would remove the original welded strutbars to put something like the bracket or the ultra racing strutbar, but I think tomorrow I'll go to the dealer and see what they say.
Thanks GuidoK.
I'll post my updates here in the following days.

 

[GuidoK]

Not sure how they would remove the original welded strutbars to put something like the bracket or the ultra racing strutbar,

The ultra racing strutbar can be fitted without doing anything to the original brackets; It goes over it.
I use one of those original brackets as a mounting point for a custom catchcan setup (to perfect the supercharger setup that I have) :roll:

 

[BMW_User]

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[BMW_User]

Update.
I went to a BMW dealer.
They were aware of the possible option of a triangular strutbar.
We've decided to weld the existing strutbar and that should be more solid than the original one.
When I'm back in the UK, depending on the state of things, I will seek advice from my mechanic to see what they suggest.
The creaking noise has now disappeared and it looks like everything is back to normal.