The X3 gusset kit is a great add on and a must for hard drivers or people that want to keep their machine straight and true. It adds rigidity and strength to the front of the machine and is going to be a must for people wanting to add a winch to the front of their X3.
This kit is designed for cars with the Smart Lock front diff or the Halo full billet front diff but will work with all models.
We started our kit with a higher grade steel than most use, grade 50 over the common A36. Grade 50 has a higher yield and tensile strength than A36 plate, combined with a lower weight making it a stronger and better option for our gussets. While A36 material isn’t a terrible option its also not our first but what others tend to use due to cost. It tends to stretch and when you’re trying to use this material as a gusset it’s less than ideal. You won’t find many places advertising their material choices and why.
Our kit consists of 4 individual pieces plus hardware.
We’ve created a plate system that ties the front mounting points along with the upper rear mount together in full. The front of the X3 is what we call a floating front end. The front of the chassis ahead of the front a arms attaches via the front arms and is only supported by the radiator. Our bulkhead assembly within the gusset kit fixes that. This is the same void in the frame where the front of the a arms pivot. The front of the frame no longer floats at this point and is tied into firmly with the rest of the chassis. Above the diff we have 2 different pieces of metal that tie the rear upper pivot point to both front a arm points. This not only strengthens the frame from the bolts trying to pull out but it greatly reduces the chance of the frame twisting. The final plate piece is additional reinforcement to to the rear lower mounting points of the suspension and finishes the gusset kit.
Standard install time is roughly 5 hours and a mechanical background or general handy work is advised. The majority of the front suspension needs to be removed, the diff does not need to be loosened and moved around for the install of this kit. Detailed instructions with pictures are included.